So I decided to solve my problem once and for all - I installed a 2000 watt, 120V electric heater element in my new brew pot. Now I can bring my wurt to boil in 50 minutes or if I'm really in a hurry I can put the brew pot on the stove AND plug in the electric heater and bring my wurt to boil in less than 25 minutes! This conversion can be plugged directly into a 20 amp kitchen outlet because it only draws 16.6 amps, or it can be plugged into our soon to be released electric brew pot controller.
I used a 32 quart Polar Ware brew pot because I believe they are an excellent value for the money. They aren't over priced like some of the brewpots on the market today but they aren't flimsy stainless steel like the cheapo Chinese brewpots either.
For more information, see http://www.kegkits.com/electricbrewpot.htm.
Step 1: Disclaimer and Parts List
This is a step by step guide for doing your own install but first I need to warn you - Drilling holes in your Polar Ware Brew Pot will VOID YOUR WARRANTY!
Also, don't hold me responsible if you screw up your install. These instructions are as complete as possible but we all have different mechanical abilities. If you are unsure about any of this then please invite a friend to help and celebrate with a few beers after the project is done.
Parts List (most parts available at Lowes and Home Depot):
1 – 2000 watt 120V screw in style water heater element
1 – Water tight electrical box with three 1/2" holes
1 – Water tight electrical box cover
1 – 1/2" cord connector
1 – 1" NPT Pipe Stainless Steel Lock Nut (P/N K419-16, available from our web site for $7.95)
1 – 14 Gauge, 16 Amp rated Power Cord (P/N 109284, available from our web site for $11.95)
3 – Ring terminals
1 - Polar Ware 321BP Brewpot
These parts are also available as a complete kit from amazon.com.
We also offer a 240V version of this kit with a Camco 02962/02963 5500W 240V Screw-In Lime Life Ripple Water Heater Element on Amazon.com.
Drill - To drill holes in your nice new brew pot
Small drill bit - to start hole
3/8" drill bit
1/2" conduit punch
1" conduit punch
Ideal P/N 36-305 Carbide Tipped hole cutter
Drill press - hand drill can be used, but dril press is much easier
Heater element socket
Large slip joint pliers
#2 plillips screwdriver
1" adjustable wrench
Step 2: Start With a Perfectly Good, Leak Free Brewpot
Step 3: Drill a Small Hole Where the Element Will Be Mounted.
I pre-measured by placing the water tight box on the side then I moved it up about 1/2". This makes sure the box is mounted high enough so that the pot is not straining the box when it's sat on the counter.
Step 4: Oh, and Congratulations, You Just Ruined a Perfectly Good Brewpot
Step 5: Open the Hole Up With a 3/8" Drill Bit.
Step 6: Insert the 1/2" Greenlee Conduit Punch and Tighten Intil the Punch Pulls Through.
Pic 2 - Punch on outside ready to tighten
Pic 3 - Punch on inside ready to tighten
Pic 4 - Tightening punch with adjustable wrench
Step 7: Now Insert the 1" Greenlee Conduit Punch and Tighten Intil the Punch Pulls Through.
Pic 2 - 1" punch on inside ready to tighten
Pic 3 - Tightening punch with adjustable wrench
Step 8: A Picture of the Finished Hole
Step 9: Inside of Water Tight Box.
Notice the green screw? You will attach the power cord green ground wire to that screw later.
If you drill the hole dead center the boss the green screw is in will be in the way of the water heater element. So you have to drill the hole off center - see below.
Step 10: Here's Where a Drill Press Helps a Lot.
Step 11: Here Is a Better Picture of the Hole Partly Drilled
Step 12: Layout the Parts That Will Be Inserted Into the Brewpot
Step 13: I Originally Thought a O-ring Seal Would Work Better
I assembled everything with the O-ring but no matter what I did the connection leaked water. I pulled the O-ring seal out and installed the original water heater seal and I had no problem making the connection water tight.
Step 14: Drop the Element Into the Inside of the Water Tight Box Then Insert It Into the Brewpot
Step 15: Push the Seal Onto the Threads As Far As It Will Go
Step 16: Thread on the Stainless Steel Nut and Hand Tighten As Tight As You Can
Step 17: Hold the Nut With a Pair of Slip Joint Pliers
Step 18: And Tighten the Water Heater Element With a Water Heater Socket
Step 19: Don't Forget to Leak Test Before You Go Any Further!!!!
We had to tighten the nut until the stainless steel side was almost flush against the nut before our brewpot was water tight.
Step 20: Straighten the Box
Step 21: For Power, Use a Power Cord Rated at 16 Amps or Higher
DO NOT USE A SMALLER GAUGE, LOWER RATED OR LONGER POWER CORD!
Step 22: Go Ahead and Feed the Wires Through the 1/2" Cord Connector.
Step 23: Trim the Wire Ends
Step 24: Feed the Wires Into the Box
Step 25: Attach the Wires to the Element
Then attach the white & black wires to the water heater screws. I put the black on top and white on bottom but the order does not matter.
Step 26: Thread the Cord Connector Into the Box & Tighten
Step 27: Install the Box Cover
Step 28: Completed With the Element Starting to Heat!
Step 29: To Use the Pot, Plug It Directly Into a 20 Amp Kitchen Outlet.
Or you can use our new Brew Pot Boil Controller.
With our boil controller, you will be able to adjust the rate of your boil.
Our 240V brew pot boil controller is available through Amazon.com.
And our 120V brew pot boil controller is also available through Amazon.com.