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How to Build a Fermentation Chiller

One of the challenges of homebrewing is how to keep a batch of beer at the proper temperature while it is fermenting. Heat is not a problem so long as you are brewing indoors; the problem is keeping the wort (fermenting beer) cool enough. While fermentation will certainly occur at normal room temperatures, the end result usually tastes better if you keep it between 50 and 65 degrees Fahrenheit, depending upon the exact style of beer you are brewing. A home-built fermentation chiller is a simple, inexpensive way to accomplish the desired result.

Things You'll Need

"Son Of Fermentation Chiller" plans
One 4 by 8 foot sheet of 2 inch thick polystyrene insulation board
Ruler
Square
Permanent marker
Saw
Construction adhesive
Masking tape
3-inch, 12-volt fan
12-volt power supply
18-gauge insulated wire
Drill with 1/4-inch bit
Mechanical thermostat
Four 1-gallon plastic jugs

Instructions

- 1
  Mark the following rectangular sections on the insulation board, according to the listed dimensions: Front, 28 by 16 inches; Rear, 28 by 16 inches; Fan, 28 by 16 inches; two Sides, each 29 by 32 inches; Top, 29 by 16 inches; Bottom, 29 by 16 inches, and Baffle, 24 by 7 inches. Cut the sections out with the saw.
- 2
  Cut a 3 by 3-inch square out of the two corners on one end of the "Fan" panel. Glue the fan into one of the two notches.
- 3
  Glue the "Baffle" panel between the "Fan" and "Rear" panels so that they form an I-beam. The "Baffle" is shorter than the "Fan" and "Rear" panels, so make it flush with the end that the fan and its opposing notch is on. According to Ken Schwartz' "Son of Fermentation Chiller" plans, this will force the air to flow across both frozen bottles to maximize the cooling effect.
- 4
  Lay the "Bottom" panel on the floor. Glue the I-beam onto the "Bottom" panel so that the fan is at the top and the "Rear" panel aligns with the edge of the "Bottom" panel.
  
  Glue the "Side" panels to the "Bottom," "Rear," and "Fan" panels. Set the "Front" and "Top" panels in place without glue, and secure the structure temporarily with tape so that it retains its shape until the glue sets.
- 5
  Drill a hole in the side of the box near the top adjacent to the "Fan" panel, on the side opposite the fan. Push the wires from the power supply through the hole.
- 6
  Connect the negative wire from the power supply to the negative terminal of the fan. Connect the positive wire to the "RH" terminal on the thermostat. Connect a piece of wire from the "G" terminal on the thermostat to the positive terminal of the fan.
- 7
  Glue the thermostat to the "Fan" panel opposite the fan, near the top of the carboy chamber (the side away from the baffle).
- 8
  Fill the jugs with water and place them in a freezer. When you are ready to use the chiller, place two of the frozen jugs into the baffle chamber; one on each side of the baffle. Plug the power supply into a wall outlet, and set the thermostat to the desired temperature. Swap the jugs every two to three days with the two remaining in the freezer.

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