Here's a few of the pics I took.
This is the 'false bottom'. Basically drilled holes in the bottom of the bucket, cut up an IKEA splatter guard and then cut some 6mm ID / 8MM OD gas line long ways to form a fairly rigid rim around the edge of the splatter guard. This perfectly seals it against the side of the bucket and should stop any grain from getting around it and also stop it from floating up off the bottom. However it can still easily be removed for cleaning just by pulling up the handle.
This is the lower lid with holes drilled into it to act as a wort return. I started off with just the small holes and it worked great however if the bucket was on an angles the wort would go over the sides too much, so I cut the big holes, but that ended up being a bad idea as the wort just goes straight for the big holes now. I'm going to drill out the small holes into medium holes and I think that should result in fairly equal wort distribution and create a shower like affect into the bucket. The upper lid is the same lid but with only a hole in the centre for the wort return tube to go into.
This is a
mock up only of bucket suspension using the urns in built handles. I am going to using some different wood to make something that fits very snuggly into the handles and very snuggly into the bucket so hopefully it'll support the full weight and not allow the bucket to move around at all. I did prefer the idea that someone here came up with which was to use wire hooks attached to the bottom of the bucket, but I don't have any stainless wire and if just using two shaped planks of wood works it'll be easier to construct at least for the first iteration of this design.
By the way total spend so far:
- Bucket: $13
- Splatter guard: $6
- Gas line approx: $1 (I had this already)
And pump related (I am going to test this system with and without the use of a pump):
- Pump: $40 (to the door in AU)
- Wort return tube: $3
- Hose clamps: $5
So without the pump this may end up cheaper than buying a BIAB bag.