More wort than expected...

[CapnK]

Yep. Got better connectors for the hoses, and going to test the coil (in isolation) again one day soon...

 

[MHB]

You can pressure test just by folding the outlet hose in half, wrap a bit of tape around it or a clamp of some sort and you will be able to test with the full pump pressure.
It is very unlikely that there is a leak in the pipe that only happens occasionally
It will almost certainly be leaking around where the hoses join the copper and trickling down the copper and into the kettle. get some decent hose clamps on there, those screw jobs can be very erratic.

If you can bend the top 90o bends down a bit further any leakage will run down the hose away from the kettle rather than into it, from the pick it looks like you have plenty of excess copper pipe, to avoid kinking the copper pipe, if you know a plumber they will have benders, or you can get a bending spring for annealed copper from any hardware store (not very expensive), just make sure the pipe is annealed.
Mark

 

[CapnK]

Actually I'd been thinking about some kind of ring around the tube to cause a drip point, as the coil might need to be re-shaped a little for a planned upgrade to a keggle which is taller.
Bending down now and re shaping later might be a bit much

(Edit, accidental double post)

 

[CapnK]

Brewed today with the slightly modified chiller, and didn't get any extra wort

Double clamps, a little teflon tape and gently bent the copper down so any sneaky leaks couldn't run down into the urn.