50′ Dual Coil Copper Immersion Chiller Build

This is my dual coil chiller. I opted for 3/8″ ARC Type L tubing below the split, and 1/2″ above the split. The 1/2″ parts are rigid Type K copper.
I needed reducers from 1/2 rigid to 3/8″ tubing in order to make the connections. I couldn’t source them locally so I needed to order them online. Because of the switch from soft tubing to rigid, you actually need to use 1/4″ to 1/2″ fittings. They are pretty rare. I found some on Amazon that were pretty pricey for what they were, but they got the job done.

 

coiling-copper1
I used a kitchen pot which was the right diameter to fit the inside of my boil kettle. In my case that was about 10″.

 

coiling_copper2
Starting to form the copper around the pot.

 

coiling_copper3
Almost done with one coil.

 

test_fit

Test fitting the coils in the pot.

2_coils
The two coils after bending. The next step was to interlace the coils.

 

y-parts-2
Various Fittings

 

Misc. parts for the splitter
Misc. parts for the split-er

 

almost_finished
This is the chiller when it is almost done. You can notice that I used some copper wire to stitch the coils together to keep it all rigid.

 

cleaned_parts
The various parts of the Y split-ers before being soldered.

 

copper_clip
I wanted to include a recirc line for my pump on the chiller. I didn’t want to hard solder it onto the chiller so I could separate it and clean it. I came up with this solution. I took a copper sweat union, cut it length ways, then used a sheet metal pliers to bend it into the shape shown. I made two and soldered them back to back. I inserted a piece of copper wire between them in a ‘U’ shape to let it take more solder and strengthen the joint.

 

finished_chiller
The finished product.