Kieth, I do 1.5 all the way down to 5/8 gal with it. Very nice little cooler for small batches.
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Cool, looking forward to having some real homwebrew on tap/bottle again. I might hit you up on your weldless cooler conversion if what I have doesn't work.
My previous setup didn't really work all that well. The rubber ring that came with the cooler compressed a bit and sucked into the opening for the valve. It didn't leak but it was only a matter of time.
I picked up a new cooler on clearance and the newer one had a beveled ring. The inner ring protrudes out of the face a bit and the outer ring fits snugly to the opening. The inner ring also has the advantage of fitting snugly into the opening made by my biggest step bit.
The result was that the inner ring on the washer is pushed slightly against the inner wall of the cooler and flares out a bit when tightened. Perfectly watertight seal.
I used 6 components altogether:
A large 5/8 fender washer on the outside of the cooler for stability
1/2 Brass Male barb on the exterior
1/2 Brass ball valve
1/2 1.5" long brass nipple
1/2 Brass female barb
5/8 thin washer between the female barb and rubber ring.
Leak tight and works like a charm.
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