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READ CAREFULLY: This item is only the upgrade kit that allows you to pull in 2" TC weld ferrules if you've already purchased the 1/2" NPT pull through tool in the past. If you do not already own that tool, you're looking for either the complete TC pull tool or the combo tool.
This tool creates a flared opening in kettle walls, bottoms, lids, etc for install of 2" 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 1-5/8" hole in your pot using either a step bit or a 40mm 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 1-5/8" 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.
Do you care about Economics?
| Process | Tool/Labor Cost | TC port | Total for 1 | Total 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.
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