[thomasben]

We got a leak coming from the front of the cooler

You can't see the leak but it seeps right at the base of the silver washer.


The inside looks good

[thomasben]

Im very open to suggestions ...a leak isn't fun on a brew day!

[alcaponejunior]

I have a similarly built one and I used o-rings internally to help seal/seat the pipe that goes through the cooler wall.  It's actually got four o-rings internally (actually inside the wall, around the pipe), then the seal that came with the cooler on the inside wall, and another o-ring sealing where the external washer hits the outer wall.  It doesn't even seat all that tightly, but it seals fine.  Might be worth a shot.  Otherwise I'd suggest going to the hardware store and figuring out how to make a better seal than what you've got. 

[erockrph]

I had a leak in the front I couldn't get rid of when I initially built my mash tun. Ended up buying a pack of hose o rings at home depot and sliding a few extra ones on and that solved the problem.

Also, sometimes less pressure is better. Only tighten until everything is just snug. Too much pressure could warp one of the o rings and lead to a leak.

[bigchicken]

I tried several combinations of o-rings and washers with no luck. I bought food safe aquarium silicone and that has sealed it up. Apply to the inside of the tun.

[Alewyfe]

Also, sometimes less pressure is better. Only tighten until everything is just snug. Too much pressure could warp one of the o rings and lead to a leak.

+1...quite important not to over tighten.

[davidgzach]

I use this Water Weld by JB Weld.  It's done great for me.

http://www.jbweld.com/product/j-b-waterweld/

Dave

[mrcceo]

Had the same problem with a cooler I recently fitted up.  The orange o-ring washers wouldn't seal.  Went to the big box store and found a 1/16" thick neoprene fender washer 1-1/2" in diameter.  Enlarged the hole to accommodate the nipple, placed one on the inside and one on the outside and it sealed like a charm.