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Install Tool (pull through flaring) for 1.5" TC Weld Ferrules
Install Tool (pull through flaring) for 1.5" TC Weld Ferrules


 
Our Price: $29.99

Quantity in Stock:74

Product Code: PTBULKHEAD_TOOL15TC
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Description
 
This tool creates a flared opening in kettle walls, bottoms, lids, etc for install of 1.5" TC weld ferrules. Once the ferrule is installed, it is well prepped to receive a bead of silver solder for strong permanent (or not) install.

Here's how it gets installed using the one step pull-in method:
  • Drill a 1-1/4" hole in your pot using either a step bit or a 32mm tungsten carbide hole saw.
  • Deburr the hole (file or sand the sharp edges). If you used a step bit, you can use it to deburr the hole by running it on the other side of the hole.
  • Degrease the pot wall, TC ferrule, and tapered bullet mandrel with acetone, etc.
  • The bolt of the install tool remains installed through the large cup die and that assembly goes inside the pot with the threaded side of the bolt sticking out through the 1-1/4" hole.
  • On the outside of the pot, the narrow end of the bullet mandrel is slid onto the bolt, followed by the TC ferrule, two fender washers, a smaller flat washer and finally the nut.
  • Hand snug the nut until everything is firmly in place. Wiggle the bolt in a few directions to be sure everything is centered.
  • Apply liquid flux to the fitting on the inside of the pot. This will ensure flux coverage when the fitting is pulled into place, but also acts as a lubricant.
  • With a pair of wrenches of some sort, tighten the bolt/nut to pull the fitting through the hole. While the mandrel is creating the flared opening, it will be difficult to tighten the nut. Once the full diameter is reached, it will be easier to tighten. When the bullet mandrel clears the pot wall, you will hear a popping sound. You will want to continue tightening another 1.5 turns.
  • Loosen the nut and take the tool out of place. You want the inside edge of the ferrule to stick into the flared opening by at least 1/16".
  • Prop the pot on its back so that the TC flange is perfectly level in all directions facing up towards the ceiling.
  • Apply a little more flux into the valley created by the flare, heat with a propane torch and apply Stay Brite silver solder to fill up the valley.
  • After cooling, clean up the area and polish the heat affected areas with bar keeper's friend or a felt wheel with polishing compound to return the area to the original luster.
Other details:

The picture shows the tool with a TC ferrule loaded in the correct location for install but does NOT include one.

It comes with a grade 5 bolt and nut, two flat washers, two fender washers, a flaring bullet mandrel and a cup die.

Optional install method for 9th level hardware nerds (there is a relatively high failure rate for this method so use at your own risk):

The standard install method outlined above is awesomely easy with the only downside being that the solder joint is done on the outside. For a slightly better outside appearance, you can flare the hole outward and then pull the TC ferrule in from the outside. We call this the FOPI method (Flare Out, Pull In).

  • Drill a 1-1/4" hole in your pot using either a step bit or a 32mm tungsten carbide hole saw.
  • Deburr the hole (file or sand the sharp edges). If you used a step bit, you can use it to deburr the hole by running it on the other side of the hole.
  • Degrease the pot wall, TC ferrule, and tapered bullet mandrel with acetone, etc.
  • The bolt of the install tool remains installed through the large cup die and that assembly goes outside the pot with the threaded side of the bolt sticking in through the 1-1/4" hole.
  • On the inside of the pot, the narrow end of the bullet mandrel is slid onto the bolt, followed by the TC ferrule, two fender washers, a smaller flat washer and finally the nut.
  • Tighten the nut/bolt until the bullet mandrel pops all the way through the hole.
  • IMPORTANT: Make sure the opening of the hole is smooth with no burrs. Any burrs will prevent the ferrule from popping back in.
  • Wipe a light coating of Harris Stay Clean liquid flux on the interior of the flared opening.
  • Load the tool with the TC ferrule in place this time exactly in reverse. The cup die goes inside the pot this time. The bullet mandrel will slightly stretch the flare open again (in the opposite direction) just enough to let the edge of the TC tubing to slip in.
  • Slowly tighten the nut/bolt. If all goes well, the TC ferrule will slide into the opening of the flare. If it starts getting hard to turn, the leading edge of the ferrule may have gotten hung up on the edge of the flare.
  • The final step is to solder on the inside of the pot.
What's that about failure rate? Yeah, it's an adventure for sure. If the ferrule gets hung up, it starts to deform the flare inward and it's enough to drive you to drink. In every test case that failed, we were able to tap out the deformity and go again. Is it for you? Probably not. Don't do it.


Do you care about Economics?

ProcessTool/Labor CostTC portTotal for 1Total for 4 ports
Weld In Ferrule DIY$1500 welder$4.50$1504.50$1518
Weld In Ferrule HIRE OUT$50 per port$4.50$54.50$218
Pull Through Weld Ferrule (soldered)$30 pull tool
$30 torch/gas
$4.50$64.50$78
Radius Faced Flange (soldered)$30 torch/gas$20$50$110
Weldless TC$13 Socket$26$39$117

Of course there are a lot of other factors to consider other than cost. The most skilled TIG welding professional possible will do a great job but only a lucky few homebrewers will have access. This pull through TC with soldering process is about as good as it gets for a DIY.

Optional Buy-Back Offer:

Consider the purchase price for this tool a deposit. If you should choose to return the tool after using it for a few installs, we will refund 2/3rds. With that spirit in mind, the tool you receive may not be pristine in appearance but will work as intended.
Average Rating: Average Rating: 5 of 5 5 of 5 Total Reviews: 9 Click Here to Write a Review »

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  0 of 0 people found the following review helpful:
 
5 of 5 Worked perfectly August 9, 2020
Reviewer: Chris Billingsley from Round Rock, TX United States  
I’ve been waiting for this to come back in stock and boy was it worth the wait!! Super easy to use gave me the ability to put 1.5” tri clamp fitting on my HLT and boil kettle for my electric elements.

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  0 of 0 people found the following review helpful:
 
5 of 5 Fantastic March 8, 2020
Reviewer: Christopher Hamilton from Satellite Beach, FL United States  
As always, never disappointed with Brewhardware.  Very intuitive design and very cost effective when compared to alternatives.  It's at a point now where I'm tempted to replace all fittings on my kettles with 1.5 TC connectors!

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  0 of 0 people found the following review helpful:
 
5 of 5 Everything is true March 4, 2020
Reviewer: Eric from Broomfield, CO United States  
I'm so impressed. This tool/technique is just fantastic. I've been looking for a good sanitary tig welder, for years, and every time I find one, they make enough money and are busy, it's hard to get a fitting put on.
Now I feel like I can make the gear, I want. Totally custom.
You need to do careful work, but it's very straightforward. It's a game changer for me! Way to go Bobby.

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  0 of 0 people found the following review helpful:
 
5 of 5 Pull through flaring for 1.5 inch tri-clover February 9, 2020
Reviewer: Allan Authier from Wallaceburg, ON Canada  
Worked amazing ! Now I need to get the 1/2 inch one also.

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  1 of 1 people found the following review helpful:
 
5 of 5 worked like a charm! July 27, 2019
Reviewer: Jared Lazorchak from Galeton, PA United States  
I flared the kettle outward and then pressed  my 1.5" ferrule into opening and worked very nicely and looks great.

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