Is there a rule of thumb when you should replace your mash tun? I've had mine about 6 years now, I was just curious.
Unless it's leaking and unrepairable, or you want to make bigger worts than you can fit in it, I'd say never.
It's seem to me that it's last for ever. the only upgrade i did to my tun is mash with a grain bag. It will help you have an easy cleaning and a very simple handling of stuck sparge . Make sure to have vegetable steamer under the grain bag to keep it last longer. On my next brow day I will post some pics.
I know I tried to take the ball-valve off a few month ago on mine. The rubber gaskets are gluing the whole setup together and I couldn't get it apart. How's everyone's rubbers holding up?
This is what I do. I did BIAB for a few batches before I got my mashtun, but I still use my doubled over extra large piece of voile in the mashtun. After I collect all my wort, I transfer the whole "bag" over to another pot with a metal rack thing that came with my turkey fryer kit. While the main wort heats up, the bag continues to drain. In 15 minutes I collect another 1/2 to 3/4 gallon of wort, then add it to the kettle. I get great efficiency this way, as there's no deadspace and I get all the sugars! Well, as much as possible, I guess.
+1 to Vikeman. Most upgrade mash tuns for want of increased capacity, increased efficiency, damage, or just for cosmetics. No worries of anything microbial, as the boil sterilizes the wort.