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How
to Build the Kegorator
"This is a description
of how to build the Kegorator"
Buy
Equipment:
A list of the equipment needed is in the
cost benefit analysis. Here is what you need to build the outside of the
Kegorator.
* Deep Freezer - 1
* Tower Taps - 2
* Drip Trays - 2
* Ply Wood 1/2'' - 5/8'' - 1
* Paint
* Mounting Brackets
Step
1:
If the freezer has been used you obviously
want to clean it first. We tested ours to see if it would hold beer
without making the beer freeze. This, to say the least, was a failure.
We cleaned the bottom and sides with bleach it worked pretty well. After
the fridge is properly cleaned. Remove the hinges from the lid. Most
chest freezer's hinges are under compression so you might need a buddy
to help you get the hinges off. Then remove the lid.
Lid
Removed
Step
2:
Sand the freezer. This is pretty easy but
if you don't have a sander you will probably want to shoot yourself. So
go ahead and invest in one or borrow one from your neighbor, uncle, or
really anyone that likes beer. After the freezer is sanded clean it off
and paint it.
Sanded
Freezer
Painted Freezer
Step
3:
After the lid is taken off you will need to
remove everything that you can down to the metal. This is pretty easy
just remember to keep all the little plastic pieces and screws that
connect everything. After the lid is removed you will need to take out
all the wires that connect to it. Most of the lids are made to be
removed so you'll probably get lucky and a plug will connect the
electronics in the lid to the main power next to the compressor but if
you don't make sure you cap the wires off with wire caps (don't cheap
out on something stupid that can cause a fire). On my freezer I had to
cut tons of stuff like the handle and the place where the plug came in
through the back. Most of this stuff doesn't matter so just cut it out
and throw it away. If you have any big holes in the lid after it is
build make sure you seal them up well.
Gutted
Lid
Step
4:
Get a piece of plywood that is cut to fit
the lid. Home depot will cut the wood to any specifications for free.
You might want to cut the wood to be a bit smaller (1/16 of an inch or
so) than necessary because the metal still has a little bit of
thickness. Once you get the wood bend the metal so the wood is able to
slide on top of the lid. Then drill and screw the wood to rest right on
top of the wood. This is important because it will help with securing
the ply wood at the end.
Drill
the Holes
Wood Inside Lid
Step
5:
Measure where you want the drip tray to go
and mark it out in the lid. You are going to want to cut the metal and
wood to make sure that it is as snug as possible. We used a dremel to
cut the metal. So cut is small you can grind and sand everything down
later. Once you get the hole cut in the metal. Use a pencil and mark it
out in the wood. Use what ever kind of saw you want to cut the wood out.
Once you have the wood and lid cut out put the wood back on the lid and
make sure everything lines up.
Wood
and Lid Cut
Step
6:
The wood and metal are naturally going to
be separated a little bit. That is ok because you can put foam
insulation in between the layers. We put a large amount of insulation in
between the lid and wood and while it was still wet we placed the wood
on top stood on it and placed the screws in the side. This is nice
because it expands when it is drying and will form to every crack and be
stronger.
With
Stuff
Step
7:
Then grind down the sides of the drip tray
to make sure that it is snug. Once it is grinded down use a hole driller
and drill a 1.5'' - 2'' diameter hole for the tower tap. We decided to
place the center of the hole 2 inches from the drip trays. If I had to
do it again I would probably drill the holes a little bit closer 1.5''
or so. After the two holes are drilled mount the drip trays with 2
brackets per tray. If it isn't flush then use washers until it is flush.
Mounted
Drip Tray
Step
8:
Sand everything on the lid and paint. Then
mount the drip trays and put the lid back on the freezer. Once the
hinges are back on cut that little plastic piece that goes on the belly
of the lid to run the lines for the tap and drip trays. Once you have
all the holes drilled mount everything and put everything together. From
there hook up all kegs, CO2, etc.
Fully
Assembled Kegorator
Pouring Beer
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