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:
- Angle grinder with handle that attaches to the top of the head.
(I bought a Porter Cable pc750ag from Lowes for $39)
- Flapper disk for angle grinder ($5 at Lowes or Home Depot)
- Stainless Steel cutting disk for angle grinder. ($5 at Lowes or Home Depot)
- Flat head screw driver
- Hack saw
- Drill and drill bit
Parts you'll need:
- 6 inch stainless steel hose clamp
- 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
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.
- Use a measuring tape to measure a half inch from one end of the pipe coupling.
- Mark with a sharpie all the way around the pipe at 1/2 inch.
- Measure the width of your angle grinder's handle. Mine was just about 1.18" or 3cm.
- Now look straight down at the coupling and hold the angle grinder handle across the end of the coupling.
- Use your sharpie to make cutting reference marks on the end of the coupling.
- Remember we are trying to cut channels or openings for the angle grinder handle.
- Use your hacksaw to cut into the coupling about half inch at each of those reference marks.
- Use a pliers or dremel to finish opening the channels. Take your time!
- Fit the angle grinder handle in the channel and test for fit.
Step 2: 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.
- Clamp the coupling down so you can drill through it.
- Find a drill bit that is about the width of your hose clamps.
- 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.
- Drill through both sides of the coupling. Take your time!
- Test the hose clamp for fit.
Step 3: Step 3 - Prep the Keg
Big Picture for this step: Prepping the keg
- 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.
- 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.
- Assuming that your keg is prepped. Move the keg to the garage or outside.
- Attach the stainless steel metal cutting disk.
- 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.
- 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
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.
- Make sure you have 360 degree movement around the keg.
- Make sure your angle grinder has a long enough cord.
- Make sure you have several feet of room around the keg.
- Without turning the Angle Grinder on move the grinder around in a circle. See if it moves freely. Sometime Keg handles are bent.
- Ok, start up the angle grinder.
- 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.
- It takes about 5-10 minutes and the keg top will drop.
Step 5: Step 5 - Sand the Edges
Big Picture for this step: You've cut the top, now sand off the lip of the new hole.
- BE CAREFUL! The lip on the new hole will be very very sharp with strands of sharp metal.
- Change your cutting disc to the flapper disc.
- Simply sand the edges of the new hole till they are smooth to the touch.
- Take your time on this step because no one likes blood in their homebrew.
- I found that a pot lid for 11.25" should work.