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You want too look into the design of of a "weldless bulkhead". The instruction/installation guide (PDF) has a great breakaway view of the approach: using nipples, couplers, washers, orings and a locknut to compress the orings against the cooler walls to create a watertight seal. The trick is to get all the pieces appropriately sized, and to use a locknut ...


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You can use my method. Take a look at www.dennybrew.com. I've used it for 17 years and 475 batches and it works perfectly. You use a minikeg bung and a nylon valve. I've found it much easier to build and more effective to use than a bulkhead.



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