I have found instructions on how to convert kegs, using reciprocating saws, grinder, and plasma cutters. But in my experience, kegs which are ground or sawed generally produce uneven or oval openings. Plasma cutters on the other hand produce outstanding openings; unfortunately I don't have many friends who have them at their disposal. So I came up with a different way of cutting the opening. In essence, I have created a hand turned lathe for a keg. It cost me around 30 dollars, but depending on your own personal inventory of tools, the cost may be higher or lower. The project took about 3 hours which included the construction, cutting out the opening and smooth out the edges.
Note that working with tools and metals always have the potential to cause harm, therefore I explicitly state that none of this information is guaranteed NOT to make you suffer an injury, lawsuit, material economic loss, time in jail or impotence. I refuse to take any responsibility for anything that happens to you as a result of using the advice stated in this instruction set. In short if you feel responsible enough to take on the project, then you are responsible enough to deal with the consequences of your own actions.
Step 1: Tools Used on the Project
The image below has been color code to help you identify what each item is and when each item is used. Yellow designates the set-up process (Phase 1), Green the cutting process (Phase 2), and Blue the clean up process (Phase 3). The Brown color denote items which are used in more than one phases.
A: Small Vise
D: Drill bits
E: Tape Measure
F: Screw driver bit.(use the one which match your fasteners)
G: Lathe Tool Holder.
H: Wrench sized for Tool Holder
I: Tool Steel Lathe Bit
K: Half round steel file
L: Aluminum Oxide Sand Paper
M: Aluminum Oxide Spindle Sander
N: Drill/Screw Driver
O: A paper towel.
Other tools "Not Shown":
If you are using an unaltered keg you may need a pair of needle nose pliers, and a firm rubber mallet.