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The solution I use is to mark my spoon with permanent marker. I have marks for each half gallon. Works really well without messing with the kettle itself. This obviously is kettle specific, so if you are using multiple kettles you can have markings of different color to differentiate the different markings per kettle.

I use an aluminum yardstick, which let's you do pretty accurate measurements on multiple pots/kettles, without needing to use a marker on anything (I've had problems with marker wearing off and worry about toxicity of the ink). Put a gallon of water in your pot, measure how high it is, and write it down somewhere. Then you'll always be able calculate what ...

I use a 5500W reliance element for boiling 56L wort (ca. 15 gallons) on about 80% duty which gives a vigorous boil. This is the typical pre-boil volume for hitting 10 gallons packaged beer. The element uses a 1" NPS thread (although check carefully - there are also elements with 1-3/8" thread.) You can get 1" NPS locknuts at bargainfittings.com. There's a ...

I have aluminum HLT and BK and used a dremel to make a small mark at each gallon level. I marked with a china marker when the water was in there (adding one gallon at a time), and after I dried it out, I used the dremel. I marked in 3 columns, 120 degrees apart, so I'd be able to see at least one measurement no matter which side I was standing on. Also, I ...

I'm a little late to this question, but I thought one solution might be to put down a layer of fiberglass fabric, the kind that is impregnated with epoxy to form fiberglass hulls and such. In its fabric form it is easy easy to lay down underneath and around the burner, non-conductive (if you have electric burners), impervious to heat, and an excellent ...

Aluminum is cheaper and easier to find, copper is a better conducter of heat. So I would probably go with aluminum and I would look at the Home Depot or Loews. They should have some sheets there. Then I would cut it to size and throw my pot on it the next time I brewed. Worst case, you can only find five inch wide strips, I would cut the strip into the ...

One thing I did in my apartment was to get a griddle that would cover 2 burners. Put both burners on high, with the griddle on top. Put the brew kettle on the middle of the griddle. You get somewhere around 1.5 the BTUs of 1 burner (some is lost to waste heat, unless you rig up a proper way to hold that heat in, which I never really investigated).

Electric brewing with heat sticks. Or you can supplement your stove top with a little extra heating capacity using a heat stick. Start here with this heat stick page Listen to the April 29th 2010 Electric Brewing episode at Basic Brewing Radio.