Introduction: Keep It Simple - How to Cut the Top Off a Keg to Make a Keggle

Picture of Keep It Simple - How to Cut the Top Off a Keg to Make a Keggle

The hardest part of turning a Keg into a Keggle is cutting the top off.

I found a really easy and simple method that will take about 5 - 10 minutes to make and 5 - 10 minutes to execute.

Tools you'll need:

  1. Angle grinder with handle that attaches to the top of the head.
    (I bought a Porter Cable pc750ag from Lowes for $39)
  2. Flapper disk for angle grinder ($5 at Lowes or Home Depot)
  3. Stainless Steel cutting disk for angle grinder. ($5 at Lowes or Home Depot)
  4. Flat head screw driver
  5. Hack saw
  6. Drill and drill bit
  7. Pliers

Parts you'll need:

  1. 6 inch stainless steel hose clamp
  2. 2 inch outside diameter by 2 1/2 inch long slip coupling.

Step 1: Step 1: Mark and Cut Channels for the Angle Grinder's Handle

Picture of Step 1: Mark and Cut Channels for the Angle Grinder's Handle

Big picture for this step: You are trying to cut openings or channels on either side of one end of the pipe to hold the handle of the angle grinder.

  1. Use a measuring tape to measure a half inch from one end of the pipe coupling.
  2. Mark with a sharpie all the way around the pipe at 1/2 inch.
  3. Measure the width of your angle grinder's handle. Mine was just about 1.18" or 3cm.
  4. Now look straight down at the coupling and hold the angle grinder handle across the end of the coupling.
  5. Use your sharpie to make cutting reference marks on the end of the coupling.
  6. Remember we are trying to cut channels or openings for the angle grinder handle.
  7. Use your hacksaw to cut into the coupling about half inch at each of those reference marks.
  8. Use a pliers or dremel to finish opening the channels. Take your time!
  9. Fit the angle grinder handle in the channel and test for fit.

Step 2: Step 2 - Cut the Two Holes for the Hose Clamp

Picture of Step 2 - Cut the Two Holes for the Hose Clamp

Big picture for this step: The handle will need to be secured to the coupling with a hose clamp.

  1. Clamp the coupling down so you can drill through it.
  2. Find a drill bit that is about the width of your hose clamps.
  3. Use your sharpie to mark a spot on the coupling that is perpendicular to the channel and about 1inch from the end of the coupling.
  4. Drill through both sides of the coupling. Take your time!
  5. Test the hose clamp for fit.

Step 3: Step 3 - Prep the Keg

Picture of Step 3 -  Prep the Keg

Big Picture for this step: Prepping the keg

  1. If your Keg still has a valve in it, then you need to make sure it is NOT under pressure. Don't proceed unless you are sure that the keg is depressurized and the valve is out.
  2. Search Google to find out how to depressurize a keg and take the valve out. There are plenty of videos on Youtube that show you this step.
  3. Assuming that your keg is prepped. Move the keg to the garage or outside.
  4. Attach the stainless steel metal cutting disk.
  5. Hook up the angle grinder to the Keg jig (the coupler). Slide the Keg jig all the way to the base of the handle and tighten with a screwdriver.
  6. Get Eye and Ear protection. Wear gloves, long pants and shirts. Cutting steel is very loud and there will be sparks.

Step 4: Step 4 - Cutting the Keg Top

Picture of Step 4 - Cutting the Keg Top

Big picture for this step: The keg jig will allow the angle grinder to scribe or cut a circle in the top of the keg.

  1. Make sure you have 360 degree movement around the keg.
  2. Make sure your angle grinder has a long enough cord.
  3. Make sure you have several feet of room around the keg.
  4. Without turning the Angle Grinder on move the grinder around in a circle. See if it moves freely. Sometime Keg handles are bent.
  5. Ok, start up the angle grinder.
  6. Use some pressure to scribe a circle around the top of the keg. Instead of trying to cut through the steel in one pass, try multiple passes.
  7. It takes about 5-10 minutes and the keg top will drop.

Step 5: Step 5 - Sand the Edges

Picture of Step 5 - Sand the Edges

Big Picture for this step: You've cut the top, now sand off the lip of the new hole.

  1. BE CAREFUL! The lip on the new hole will be very very sharp with strands of sharp metal.
  2. Change your cutting disc to the flapper disc.
  3. Simply sand the edges of the new hole till they are smooth to the touch.
  4. Take your time on this step because no one likes blood in their homebrew.
  5. I found that a pot lid for 11.25" should work.

Comments

shortfatguy (author)2016-05-12

JUST A CAUTION,IF A KEG OF BEER IS PURCHASED FROM A SELLER OF BEER, YOU ARE BUYING BEER AND "RENTING THE KEG" WITH THE REQUIRED $20-$30 DEPOSIT. IT IS A CRIME TO ALTER WITHOUT ACTUALLY PURCHASING FOR THE REAL VALUE.

TioFrio (author)2014-07-05

I'm sure a keggle is cool and this looks like a cool project, but you don't say what a keggle is or why I would want or need one. It looks like a neat barrel. Is that what it is about?

paularellano12 (author)TioFrio2014-07-30

Keggels are brew kettles converted out of a keg. Common in homebrewing brewers will add a heating element or simply put the stainless steel keg over a propane burner to brew the beer that they want. It's a cool and inexpensive way to brew 15 gallon batches of beer. Hope this shed some light on this instructable. Attached are some pictures of a all electric brew setup I have done. I power coated my kegs white with the hop gernade logo embedded in the side.

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