Having fought most of the battles with my King Kegs that most of you with plastic pressure barrels have already fought, got the T shirts and video, I’ve just completed a project to, hopefully, improve the reliability of my kegs regarding leaks.
I posted some pics of a prototype cap I had produced using aluminium plate and part of the original cap. Well, I’ve refined that a bit further and thought I’d share with you the result...
I made a couple of silicone rubber moulds to cast the collar and top from acrylic. The collar moulding had to be finished (cut and drilled) so it could act as a clamp on the barrel neck.
The collar is screwed on to the barrel neck and the clamp tightened to remove any play in the threads.
I used 2mm thick nitrile rubber sheet to make a washer/gasket that sits on the barrel neck face,
The top casting, which was just a 10mm thick disc, had to be drilled out for the securing bolts and also holes for the pressure gauge assembly and a Schrader valve for leak testing and injecting CO2.
Wing-nuts and washers clamp the top down,
and that’s it, the Buffers Brewery Pressure Barrel Bung!![aLaugh8 :laugh8: :laugh8:](http://www.mysmiley.net/imgs/smile/happy/happy0157.gif)
Not a rubber band in sight and you can see the join between the lid and barrel neck for leak testing.
I posted some pics of a prototype cap I had produced using aluminium plate and part of the original cap. Well, I’ve refined that a bit further and thought I’d share with you the result...
![3B32D284-126F-495B-8397-8CC02DD3B0DB.jpeg 3B32D284-126F-495B-8397-8CC02DD3B0DB.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23817-3B32D284-126F-495B-8397-8CC02DD3B0DB.jpeg)
I made a couple of silicone rubber moulds to cast the collar and top from acrylic. The collar moulding had to be finished (cut and drilled) so it could act as a clamp on the barrel neck.
![15FED6B5-CF40-4E93-BF4F-0B7FD573B05D.jpeg 15FED6B5-CF40-4E93-BF4F-0B7FD573B05D.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23820-15FED6B5-CF40-4E93-BF4F-0B7FD573B05D.jpeg)
![D7D98428-8858-405F-8118-C820715499BC.jpeg D7D98428-8858-405F-8118-C820715499BC.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23821-D7D98428-8858-405F-8118-C820715499BC.jpeg)
The collar is screwed on to the barrel neck and the clamp tightened to remove any play in the threads.
![E33089CB-D8F8-44B3-B148-794DB9AC9DAD.jpeg E33089CB-D8F8-44B3-B148-794DB9AC9DAD.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23822-E33089CB-D8F8-44B3-B148-794DB9AC9DAD.jpeg)
I used 2mm thick nitrile rubber sheet to make a washer/gasket that sits on the barrel neck face,
![A6A0DE71-1377-4163-9172-DA5DC68CE913.jpeg A6A0DE71-1377-4163-9172-DA5DC68CE913.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23823-A6A0DE71-1377-4163-9172-DA5DC68CE913.jpeg)
The top casting, which was just a 10mm thick disc, had to be drilled out for the securing bolts and also holes for the pressure gauge assembly and a Schrader valve for leak testing and injecting CO2.
![A888F5DD-F3FF-412F-B88D-B87268D25D31.jpeg A888F5DD-F3FF-412F-B88D-B87268D25D31.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23824-A888F5DD-F3FF-412F-B88D-B87268D25D31.jpeg)
Wing-nuts and washers clamp the top down,
![39EE8889-235F-4143-82B1-DD195BED6975.jpeg 39EE8889-235F-4143-82B1-DD195BED6975.jpeg](https://cdn2.imagearchive.com/thehomebrewforum/data/attach/23/23825-39EE8889-235F-4143-82B1-DD195BED6975.jpeg)
and that’s it, the Buffers Brewery Pressure Barrel Bung!
![aLaugh8 :laugh8: :laugh8:](http://www.mysmiley.net/imgs/smile/happy/happy0157.gif)
Not a rubber band in sight and you can see the join between the lid and barrel neck for leak testing.