Wood Fired Kettle

These are known by a few different names (Billy, Thermette, BackCountry Boiler,  storm kettle, volcano kettle, Kelly Kettle, or Bush kettle) depending on your locale. They all work on basically the same principle of a water jacket around a wood fire to boil the water. 
The commercially available varieties are quite expensive however, and when I spotted an old broken electric jug in my favorite local dumpster, I had to have a go at making one. 
The process I used involves fabricating a cone out of the same material as the donor jug, and welding it in place, making a donut of sorts.
I've seen copper, aluminum, and stainless wood-fired kettles, this one is stainless steel, and to my knowledge is the first of its kind with transparent viewing windows in the sides. 

Materials:

• donor electric or stove top jug
• donor thermos (optional)
• sheet metal the same as your jug
• fork (optional)

Tools:

• welding setup
• Dremel tool
• drill & bits
• angle grinder

Step 1: Gut the Jug

The first thing I had to do was get rid of all the extra bits I didn't need. Fortunately I had the 3 point driver bit I needed for the tamperproof screws. With the bottom & the handle off, all I had to do away with was the heater element. Ye olde multipurpose chisel made short work of that, a few good whacks and it popped right off. 

Comments

[flamesami]

i just looked at the thermette web site 8-O !!!! it looks like it was made out of a pipe, 2 end caps and a bit of copper sheet in a cone shape, with a couple of handles and a spout/pourer-thingy...they "only" want a very reasonable 110$! what a bargin! (note sarcasm) maybe it's because they are copper that they're so expensive, but i think i'm pretty much duty bound to make one that costs as little as possible, but will serve me a lifetime...

[andrew.spencer.2]

my sentiments exactly! my relatives have one of the originals, and I thought I've got to get me one of these! I did some research, and the price was the major motivator to make my own. I actually prefer mine to theirs now, especially with the little clear viewing windows! best of luck with your own!

[Bayfielder]

If you live in an area that has a Princess Auto store (it's more surplus, hydraulics, and farm equipment then auto parts) they sell a complete "security" bit set for a decent price $13can at last check. Very useful for projects like this.

[TrailH4x]

Great looking piece of kit! Many I have been hiking with have been experimenting with manufactured stainless versions. I think there is an aluminum one waiting to be fabbed out of an old perculator kettle and some drinking water grade JB weld over in my "little building!"

[StupidGenius]

Thumbs up mate!

[bruc33ef]

Kelly Kettles are great and I've long thought that there must be a way to make one cheap and easy with household tools. Yours is a big step in that direction. Way to go!