Drilling a aluminum pot

[Thomas]

So I am thinking about installing a valve on the botom of my aluminum boil kettle. Who has some experience drilling aluminum, and any good leads fo ball valves?

[Gil Breau]

I kinda half assed drilling mine. Used a metal bit, bore the hole, and then cursed myself as I had to grind down the shavings. Mine was a SS pot though, aluminum is a bit softer if I recall.

What you really need is a step-drill bit, like this:



I thought it pricey to get it for two holes though.

Ball valve wise, I just used a bronze ball valve. Everything I've read says the only harm from bronze comes from letting it be in contact with the wort over long periods (days), otherwise it's no different that SS. Some might debate that, but to each their own. Same with hose barbs etc. Got it all from Northeast Equipment in Saint John.

Theres a place in saint john that high temp o-rings too, and they were the perfect size to create 1/2 inch weldless bulkheads. I have the receipt tucked in wallet still, otherwise I'd forget what it was. Keep meaning to put it somewhere safer, but haven't. Think the whole setup for the valve cost me about 25 per valve. Pics are somewhere here from when I made them I believe.

[brew]

Hey Thomas - I did mine alum pot back in may or june. Generally a 7/8" hole - takes a couple of seconds - I have hole saws if you want to drop by sometime (although I'm away this weekend)...

John got me a ball valve from http://www.homebrewing.org/weldless-kettle-conversion-kit_p_1570.html - its brass so needs to be treated but otherwise its been working good for me...

[Richard]

I'll leave it up to fakr to say yes or no, but he just lent me one of those step-bits to drill some copper. If he says it's OK I'll bring it to the meeting.