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Weekend DIY Homebrew Project: Weldless Valve on Stainless Boil Kettle

I love homebrew Do-It-Yourself projects so I decided it is time to upgrade my boil kettle after getting a great deal on the highly rated Bayou Classic 44-quart (11-gallon) Stainless Steel kettle. So long, trusty 8-gallon turkey fryer pot! This new pot means no more boil overs on the garage floor for my 5-gallon batches. It also means a much larger and bulkier kettle hot water and wort to lift and dump. So, it was time to add a stainless steel ball valve to let gravity do the work or so I can add a pump in the future to transfer liquids.

The best long-term solution is to weld a valve to the pot but that is more expensive (and very permanent). The weldless kit is cheap, very easy to install, and doesn’t take much time to complete. It also allows you to add options to your pot over time, like a weldless dial thermometer and weldless sight glass.

As usual, there are excellent video resources available online to help you out. I compiled these resources to save you the time of scouring for quality info.

The Parts

Bayou Classic 44-quart Stainless Steel Stockpot – if you think you may move to 10-gallon batches in the future, go for the 16-gallon version

Stainless Weldless Valve and Bulkhead

Bazooka Screen

Optional Heat Shield – you may not need this depending on your burner, but my KAB6 burner puts out a lot heat that will melt the rubber coating on the valve handle

Teflon Tape

The Tools

Drill – make sure your battery is fully charged!


1/8″ Drill Bit

Step Drill Bit

Metal Files

Oil/Lubricant – you can use a variety of different lubricants including dishwashing soap, WD-40, Liquid Wrench, etc.

Flexible Tape Measure


Sharpie marker

Now that you have all the parts and tools, read on to see how easy it is to finish the project.

Mike Stuart

Craft beer enthusiast and hombrew dabbler. Part-time writer, sometimes funny.

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