My mods... Malt Mill, BM base, Copper Chiller and Winch...

Did you pimp your Braumeister? Show us your mods!

My mods... Malt Mill, BM base, Copper Chiller and Winch...

Unread postby lcatulo » Wed Dec 10, 2014 8:48 pm

Here they are...

1-Malt Mill (V3.0):

2014-12-10 19.27.45.jpg
2014-12-10 19.28.18.jpg


It was a manual/drill mill (140€)... This was my 3rd and last mod on it. The previous ones didn't work that well as the motors (12V and 24V) were not strong enough to crush the malt, specially if it was processed with water (processing malt (with 2% water) is GREAT as the husks are damp and aren't so finely crushed -> less trub and more efficiency).

Used a CNC machine to make the aluminum base, a laser cut machine to cut/engrave all the plexiglass. 220V motor, 15:1 gearbox and coupling are from EBAY.

On the base there is a groove that fits into a 30L bucket.


2-BM50 Base:

2014-12-10 19.22.40.jpg


My counter is not flat... Every time I brewed I had to level the BM and, at the end, had to manually tilt the BM to get the most wort...
Now the BM fits on those red spots and is ready to brew.

The base also tilts on front. I only need to connect the winch on the back and voilá... :)

CNC also used to machine the aluminum base.


3-Copper Chiller:

2014-12-10 19.25.32.jpg


I have a stainless steel chiller but it takes to long to cool the wort using just normal water...
Got 35m of 10mm copper tube to do this double coil.

Used a lathe and some tubes to coil all the copper. Then, to get it all together, some stainless steel pieces were laser cut to make a kind of frame.

I took more than 12h just to assemble the copper on the frame... :(

Now I put this chiller in a bucket with ice and water and the other one (stainless) on the wort. It takes minutes to get 40L of wort to 20ºC!


4-Tha Winch!
2014-12-10 19.21.02.jpg


This is my latest "mod"...
For those of you with a BM50 it is not easy to lift a full tube and place it to drip, specially if brewing solo... :wink:

I wanted a winch but not a BIG one. I got this one on EBAY. Choose it mostly by the small size. As it is 12V I had to make a control box to house the BIG transformer (about 120VA) the power rectifier (to turn AC into DC) and all the connections.
The original cables were "shitty" so I made those coiled ones front straight rubber cables.

The motor slides front to drop the malt pipe and then goes back to grab the base and tilt the BM.

No fuss now brewing solo! :D


And that's all for now. Hope you enjoyed it.

Drop me a line if you need any help doing some of this stuff.

Luis Catulo
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby ibbones » Wed Dec 10, 2014 8:55 pm

Wow!!! That's some serious work going on there. Looks really good.
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby Jacques » Wed Dec 10, 2014 9:39 pm

That is really neat and impressive.
Congratulations !!!
Would it be possible to get the details of the malt mill motor and gearbox ?
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby MattSR » Wed Dec 10, 2014 10:44 pm

This is a different one, but lots of brewers here in Aus have had good experiences with this package:-

http://www.motiondynamics.com.au/home-b ... oller.html
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Wed Dec 10, 2014 11:07 pm

Jacques wrote:That is really neat and impressive.
Congratulations !!!
Would it be possible to get the details of the malt mill motor and gearbox ?


Thanks Jacques,

No problem.

This is what I've used:

The motor:
http://www.ebay.co.uk/itm/320969596301?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

The Gearbox:
http://www.ebay.co.uk/itm/321061910069?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
(This will give you 187rpm at 11N.m of torque on your mill's shaft)

if you want MORE speed but LESS torque you can use this one:
http://www.ebay.co.uk/itm/321061910111?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
(This will give you 373rpm at 5N.m of torque on your mill's shaft)

The shaft (connects gearbox to coupling):
http://www.ebay.co.uk/itm/221287592690?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

The Coupling (connects gearbox and mill's shafts):
http://www.ebay.co.uk/itm/BF-10mm-X-14mm-CNC-Flexible-Plum-Coupling-Shaft-Coupler-D30-L42-SY-FUS-/271451551234?pt=UK_BOI_Electrical_Test_Measurement_Equipment_ET&hash=item3f33c5f602
(choose this based on your mill specs)


You can also buy these ready assembled but more expensive:
2800rpm + 1:15 = 180rpm with 11N.m -> http://www.ebay.co.uk/itm/Single-Phase-0-25kw-1-3hp-Bonfiglioli-Motor-and-Gearbox-180rpm-output-14mm-Bore-/321211635774?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item4ac9b4983e

2800rpm + 1:10 = 280rpm with 8N.m -> http://www.ebay.co.uk/itm/Single-Phase-0-25kw-1-3hp-Bonfiglioli-Motor-and-Gearbox-270rpm-output-14mm-Bore-/221285601078?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item3385a64f36

2800rpm + 1:7 = 386rpm with 5N.m -> http://www.ebay.co.uk/itm/Single-Phase-0-25kw-1-3hp-Bonfiglioli-Motor-and-Gearbox-386rpm-output-14mm-Bore-/331027084078?pt=UK_BOI_Electrical_Components_Supplies_ET&hash=item4d12c0732e

Torque:
Just an example:
11N.m = 1,12Kg.m -> simplifying means that you would apply 1,12Kg of strength at the end of an 1m handle connected to your mill's axis... Quite a lot!
( to get Kg.m just divide N.m for 9.8 )

The aluminum base was drawn and CNC milled based on the specs of my mill and motor:
Captura de tela 2014-12-10 22.40.03.png



Hope this helps,

rgds,
Luis Catulo
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Wed Dec 10, 2014 11:36 pm

MattSR wrote:This is a different one, but lots of brewers here in Aus have had good experiences with this package:-

http://www.motiondynamics.com.au/home-b ... oller.html


In my V2.0 version I used a similar motor/gearbox (not as good as that one), but had many problems:
-Motor heating...
-Transformer burning...
-Motor stopping with not enough "juice" to grind the water processed malt.

I could of solved it with a better motor/transformer but decided on the 220V motor. No need for an extra power supply. Much more tidy mill with less electronics... :)

Ahh... V1.0 version was with a transformed drill motor, together with all the torque gears of the drill itself...
It worked "OK" but I burned two transformers, not cheap...

As a rule of thumb, if you have a DC motor capable of a high torque, you need to feed him with a good transformer or it (the transformer) will burn.
For example my hoist (or winch...) would require about 90A (12V DC) to lift the maximum 2000lbs (about 900Kg)... That is a BIG EXPENSIVE transformer... :)

Luis Catulo
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby dinnerstick » Thu Dec 11, 2014 8:06 am

you are my hero
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby bruulog » Thu Dec 11, 2014 2:33 pm

For example my hoist (or winch...) would require about 90A (12V DC) to lift the maximum 2000lbs (about 900Kg)... That is a BIG EXPENSIVE transformer...


Use pulleys and you can lift 900 kg with a relatively tiny motor.
I make my own copper/ss chillers (immersion) - 20l & 50l and counterflow (cfc)
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Thu Dec 11, 2014 2:45 pm

bruulog wrote:
For example my hoist (or winch...) would require about 90A (12V DC) to lift the maximum 2000lbs (about 900Kg)... That is a BIG EXPENSIVE transformer...


Use pulleys and you can lift 900 kg with a relatively tiny motor.


I know... It's just a matter of adding them... Just add 4 and you "only" need 225Kg to lift 900Kg... But you also have to pull 4 times the length of cable!

Even my hoist being 2000lbs I don't need that much to pull the full malt pipe so I just installed a 30A transformer. More than enough...

Luis Catulo
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby MattSR » Thu Dec 11, 2014 8:59 pm

The combo I posted up only needs about 25A or so, there's plenty of cheap switch modes available that are small, light, cheap and up to the task.
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby Luis Coentrao » Thu Dec 11, 2014 9:42 pm

Hi Luis,

Your malt mill is the Brewferm one?
Just for curiosity, a simple Black&Decker was not sufficient to mill the processed malt?
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby niels » Thu Dec 11, 2014 10:00 pm

Wow, this is some kickass setup! I really dig the malt mill.

One day I will swap out my Metabo for a fixed motor setup.

I have a 24 VDC motor to drive the windshield wipers of a truck lying around. Low speed, high torque. It might be usable.

Thanks for creating the post and adding all the component links.

Having access to a CNC and laser cutter is my wet dream. Lucky bastard!

:cheers:
- Niels
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Thu Dec 11, 2014 10:33 pm

Luis Coentrao wrote:Hi Luis,

Your malt mill is the Brewferm one?
Just for curiosity, a simple Black&Decker was not sufficient to mill the processed malt?


Brewferm mill... Correct!

It depends on the "Black&Decker" and how much torque it has...

1-Tried a real Black&Decker (but a cheap one, not geared) and no luck...
2-Used the motor and gearbox of a PARKSIDE (LIDL) 24V cordless (this was my V2.0 version!) with an external transformer and it was ok for non-processed malt...
As soon as I tried the processed one the motor started to stop, getting very hot and bye-bye transformer... :(
3-Worked really well (processed and normal) with a 600€ BOSCH PROFESSIONAL cordless drill. But I wanted something nicer, permanent and more friendly to use... Using the BOSCH internals was stupid expensive and I also needed a transformer...

My V3 is perfect, for me... No external supply and I can throw everything at it... No stops, jams, heating and everything is tidy as I like!
Luis Catulo

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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Thu Dec 11, 2014 10:52 pm

niels wrote:Wow, this is some kickass setup! I really dig the malt mill.

One day I will swap out my Metabo for a fixed motor setup.

I have a 24 VDC motor to drive the windshield wipers of a truck lying around. Low speed, high torque. It might be usable.

Thanks for creating the post and adding all the component links.

Having access to a CNC and laser cutter is my wet dream. Lucky bastard!

:cheers:
- Niels


I also considered on of those motors, but the speed is REALLY SLOW and I'm not quite sure if the torque is enough. Grinding processed malt really pushes the motors...
Pay attention to the transformer... If the motor has enough torque you might need some Amps to feed it... Trust the guy who was able to burn at least 3 transformers... :)

You are so right! Access to this type of machines really opens much opportunities. You can make professional quality MOD's. It takes time to do it well but the results are great!

Having access to those machines has an added advantage: I can reserve my "wet dreams time" for other types of fun... :D

cheers,
Luis Catulo AKA Lucky Bastard ;)
Last edited by lcatulo on Thu Dec 11, 2014 11:24 pm, edited 1 time in total.
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Re: My mods... Malt Mill, BM base, Copper Chiller and Winch.

Unread postby lcatulo » Thu Dec 11, 2014 11:23 pm

MattSR wrote:The combo I posted up only needs about 25A or so, there's plenty of cheap switch modes available that are small, light, cheap and up to the task.


At the end, "IF" all motors have torque enough, is a matter of personal preference (how much you want/can spend to achieve your goal) and what you are aiming for.

I think the motor/gear I used is much more robust and with fewer possible points of failure... But that has a price attached to it... :wink:
Luis Catulo

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