How to build weldless/stainless bulkhead for mash tun??

http://brewing.lustreking.com/gear/mashtun.html

 

you are making this more difficult than it needs to be. i usually believe DIY is the best way, but when making a bulkhead fitting for a cooler you wont be saving time or money by sourcing all the components yourself. the fittings need to be exact or you will have a leak. buying s/s from the big box is overpriced. minor details such as the type of material the o-ring is made of will make a big difference.

get a bulkhead from NB, Midwest, Williams or some other online retailer. however, fabricate the false bottom or collection yoke yourself.

if you do want to build it yourself, spend some time at McMaster Carr or Grainger. this is just one guys advice.
Cheers.

edit, also, some online designs incorporate dissimilar metals. this is generally not OK. convenient but flawed, and your connections will eventually sieze.

 

I've had great luck with the stuff from http://www.bargainfittings.com/ - it's the cheapest I could find when doing my weldless stuff.

 

I used http://www.bargainfittings.com/ for the bulkhead/valve/barb. I used the SS braid from a toilet supply line from Home Depot as a screen with a commensurately long piece of 1/4" copper pipe with slits cut every 3/4" or so for support. Silicon tubing from Bargain Fittings as well. Small hose clamps from Home Depot to seal it all up. I've very satisfied with the flow and flow control I get.

 

I made mine, works great, been running it for over a year now, I got all my stuff locally. I did brass, but could easily do SS locally as well.

http://endofsilencebrewing.blogspot.com/2013/02/mash-tun-ball-valve-bulkhead-build.html?m=1

 

If you're a member of a homebrew club ask around your club if they have any spare SS washers. That tends to be the hardest piece to source without buying a bunch of extra crap. Somebody in the club is bound to have bought spares.