Chest freezer kegerator collar
A timber collar between a chest freezer and its lid, with taps through the front board and room for kegs and a CO2 cylinder.
Default dimensions are shown below. Enable JavaScript to edit dimensions and inspect the 3D model.
Dimensions
- outer Length
- 1,100 mm
- outer Width
- 640 mm
- body Height
- 850 mm
- wall Thickness
- 70 mm
- step Length
- 330 mm
- step Height
- 250 mm
- board Section
- 38 mm, 140 mm
- board Length
- 2,400 mm
- kerf
- 3 mm
- foam Thickness
- 25 mm
- foam Sheet
- 600 mm, 1,200 mm
- tap Count
- 4
- shank Hole Diameter
- 22 mm
- hinge Inset
- 150 mm
- keg Diameter
- 216 mm
- keg Height
- 629 mm
- coupler Clearance
- 100 mm
- cylinder Diameter
- 133 mm
- cylinder Height
- 445 mm
Shopping list
Quantities follow the dimensions above and have not been checked against a built example.
| Quantity | Item | Note |
|---|---|---|
| Timber | ||
| 2 2400 mm lengths | dressed timber38 mm × 140 mm section6 cuts · 1,214 mm offcut in total | First-fit estimate with the entered saw kerf. Check grain and defects before cutting. |
| Sheet | ||
| 1 sheet | rigid foam insulation sheets | Cut 2 at 514 × 140 mm and 2 at 1024 × 140 mm, 25 mm thick, cut out of 600 × 1200 mm sheet. |
| Fixings and hardware | ||
| 12 screws | wood screws for the corners | About 80 mm long, 3 per corner, pre-drilled. Length and count are proposals. |
| 6 screws | wood screws for the hinge blocks | Three per block into the back board, with glue. Leave out with the blocks. |
| Bought parts | ||
| 4 faucets | beer faucets | One per shank, with handles. |
| 1 tray | drip tray | At least 888 mm long. Magnetic or adhesive mount; no holes in the freezer. |
| 4 shanks | tap shanks | At least 103 mm long, for a 22.2 mm hole. Check the maker’s hole size. |
| Sealants and coatings | ||
| tube, amount not specified | sealant | Two beads beside the gasket, about 6656 mm in all, fix the collar to the rim. Pick one that bonds to the freezer finish. |
| 4 m | weatherstrip gasket | Self-adhesive closed-cell strip, at least 38 mm wide, in one 3328 mm run under the collar. |
Cutting plan
Stock allocation uses the model’s kerf rule and the default stock lengths. No piece is spliced to fit.
timber 1timber
2,400 mm- 1,100 mm
- 1,100 mm
- 120 mm
Offcut 71 mm
timber 2timber
2,400 mm- 564 mm
- 564 mm
- 120 mm
Offcut 1,143 mm
Cut list
| Part | Stock | Cut | Joint and angles |
|---|---|---|---|
| timber | 1,100 mm × 140 mm | Full length; screw through it into both side ends. 4 shank holes 22 mm across, centred 70 mm up. Saw angle from square 0° | |
| timber | 1,100 mm × 140 mm | Full length; screw through it into both side ends. The lid hinges fix here. Saw angle from square 0° | |
| timber | 564 mm × 140 mm | Fits between the front and back boards; square ends take the corner screws. Saw angle from square 0° | |
| timber | 564 mm × 140 mm | Fits between the front and back boards; a 10 mm probe passage near the top. Saw angle from square 0° | |
| timber | 120 mm × 140 mm | Glued and screwed to the back board behind a lid hinge. Leave out if the hinge fixes straight to the collar. Saw angle from square 0° | |
| timber | 120 mm × 140 mm | Glued and screwed to the back board behind a lid hinge. Leave out if the hinge fixes straight to the collar. Saw angle from square 0° |
Openings and fitted details
- id
- tap.1.hole.collar
- target
- collar.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 166 mm, 19 mm, 925 mm
- depth
- 38 mm
- status
- derived spacing; hole size from your shank
- id
- tap.1.hole.lining
- target
- lining.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 166 mm, 51 mm, 925 mm
- depth
- 25 mm
- status
- derived spacing; hole size from your shank
- id
- tap.2.hole.collar
- target
- collar.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 422 mm, 19 mm, 925 mm
- depth
- 38 mm
- status
- derived spacing; hole size from your shank
- id
- tap.2.hole.lining
- target
- lining.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 422 mm, 51 mm, 925 mm
- depth
- 25 mm
- status
- derived spacing; hole size from your shank
- id
- tap.3.hole.collar
- target
- collar.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 678 mm, 19 mm, 925 mm
- depth
- 38 mm
- status
- derived spacing; hole size from your shank
- id
- tap.3.hole.lining
- target
- lining.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 678 mm, 51 mm, 925 mm
- depth
- 25 mm
- status
- derived spacing; hole size from your shank
- id
- tap.4.hole.collar
- target
- collar.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 934 mm, 19 mm, 925 mm
- depth
- 38 mm
- status
- derived spacing; hole size from your shank
- id
- tap.4.hole.lining
- target
- lining.front
- type
- circle
- axis
- y
- diameter
- 22 mm
- centre
- 934 mm, 51 mm, 925 mm
- depth
- 25 mm
- status
- derived spacing; hole size from your shank
- id
- controller.probe-passage
- target
- collar.right
- type
- circle
- axis
- x
- diameter
- 10 mm
- centre
- 1,081 mm, 410 mm, 975 mm
- depth
- 38 mm
- status
- proposed; seal around the lead
- id
- controller.probe-passage.lining
- target
- lining.right
- type
- circle
- axis
- x
- diameter
- 10 mm
- centre
- 1,050 mm, 410 mm, 975 mm
- depth
- 25 mm
- status
- proposed
Parts
| Part | Material | Size | Basis |
|---|---|---|---|
| dressed timber | 1,100 mm × 38 mm × 140 mm | derived from your freezer | |
| dressed timber | 1,100 mm × 38 mm × 140 mm | derived from your freezer | |
| dressed timber | 38 mm × 564 mm × 140 mm | derived from your freezer | |
| dressed timber | 38 mm × 564 mm × 140 mm | derived from your freezer | |
| dressed timber | 120 mm × 38 mm × 140 mm | proposed; only if the hinge needs packing out | |
| dressed timber | 120 mm × 38 mm × 140 mm | proposed; only if the hinge needs packing out | |
| reference hinge | 50 mm × 15 mm × 130 mm | position proposed; match your lid | |
| reference hinge | 50 mm × 15 mm × 130 mm | position proposed; match your lid | |
| rigid foam insulation | 1,024 mm × 25 mm × 140 mm | derived; thickness proposed | |
| rigid foam insulation | 1,024 mm × 25 mm × 140 mm | derived; thickness proposed | |
| rigid foam insulation | 25 mm × 514 mm × 140 mm | derived; thickness proposed | |
| rigid foam insulation | 25 mm × 514 mm × 140 mm | derived; thickness proposed | |
| weatherstrip gasket | 1,100 mm × 38 mm × 5 mm | compressed thickness proposed | |
| weatherstrip gasket | 1,100 mm × 38 mm × 5 mm | compressed thickness proposed | |
| weatherstrip gasket | 38 mm × 564 mm × 5 mm | compressed thickness proposed | |
| weatherstrip gasket | 38 mm × 564 mm × 5 mm | compressed thickness proposed | |
| tap shank | 22 mm × 118 mm × 22 mm | bought; length derived | |
| beer faucet | 28 mm × 65 mm × 28 mm | bought; drawn shape, not a product | |
| beer faucet | 24 mm × 24 mm × 100 mm | bought; drawn shape, not a product | |
| tap shank | 22 mm × 118 mm × 22 mm | bought; length derived | |
| beer faucet | 28 mm × 65 mm × 28 mm | bought; drawn shape, not a product | |
| beer faucet | 24 mm × 24 mm × 100 mm | bought; drawn shape, not a product | |
| tap shank | 22 mm × 118 mm × 22 mm | bought; length derived | |
| beer faucet | 28 mm × 65 mm × 28 mm | bought; drawn shape, not a product | |
| beer faucet | 24 mm × 24 mm × 100 mm | bought; drawn shape, not a product | |
| tap shank | 22 mm × 118 mm × 22 mm | bought; length derived | |
| beer faucet | 28 mm × 65 mm × 28 mm | bought; drawn shape, not a product | |
| beer faucet | 24 mm × 24 mm × 100 mm | bought; drawn shape, not a product | |
| drip tray | 888 mm × 100 mm × 25 mm | bought; magnetic or adhesive mount, no holes in the freezer | |
| reference freezer | 1,100 mm × 640 mm × 70 mm | drawn at wall thickness; keeps its own seal | |
| reference freezer | 1,100 mm × 70 mm × 850 mm | measured by you | |
| reference freezer | 1,100 mm × 70 mm × 850 mm | measured by you | |
| reference freezer | 70 mm × 500 mm × 850 mm | measured by you | |
| reference freezer | 70 mm × 500 mm × 850 mm | measured by you | |
| reference freezer | 960 mm × 500 mm × 70 mm | drawn at wall thickness; measure the inside depth | |
| reference freezer | 330 mm × 500 mm × 250 mm | measured by you | |
| reference keg | 216 mm × 216 mm × 629 mm | your keg size | |
| reference coupler | 50 mm × 50 mm × 100 mm | your coupler clearance | |
| reference keg | 216 mm × 216 mm × 629 mm | your keg size | |
| reference coupler | 50 mm × 50 mm × 100 mm | your coupler clearance | |
| reference keg | 216 mm × 216 mm × 629 mm | your keg size | |
| reference coupler | 50 mm × 50 mm × 100 mm | your coupler clearance | |
| reference keg | 216 mm × 216 mm × 629 mm | your keg size | |
| reference coupler | 50 mm × 50 mm × 100 mm | your coupler clearance | |
| reference keg | 216 mm × 216 mm × 629 mm | your keg size | |
| reference coupler | 50 mm × 50 mm × 100 mm | your coupler clearance | |
| reference CO2 cylinder | 133 mm × 133 mm × 445 mm | your cylinder size | |
| reference regulator | 90 mm × 60 mm × 100 mm | height allowance proposed | |
| reference manifold | 30 mm × 190 mm × 50 mm | position proposed; screws into the collar, not the freezer | |
| reference controller | 30 mm × 120 mm × 80 mm | mounting position; not a product size | |
| reference probe | 8 mm × 8 mm × 40 mm | position proposed |
Build steps and tools
Measure the freezer
Measure the outer length, width and body height, the wall thickness at the rim, and the compressor step inside: its length along the floor and its height above the floor. Measure your kegs with their couplers fitted. Enter them all; the model then shows how many kegs fit.
Tape measure; a ruler across the rim gives the wall thickness.
tape measurerulerCut the collar boards
Mark the front and back boards at the full outer length and the two sides at the outer width less two board thicknesses. Cut them square. Cut the two hinge blocks only if your hinges need packing out.
Square and pencil; a mitre saw, circular saw or handsaw for the crosscuts.
squaremarking pencilmitre sawcircular sawhandsawJoin the corners
Lay the boards on a flat floor with the front and back boards over the side ends. Clamp each corner square, pre-drill and drive the corner screws. Check both diagonals match before the last screws go in.
Clamps, square, drill/driver with a pilot bit and countersink, driver bit.
clampsquaredrill driverdrill bitcountersink bitdriver bitBore the shank holes
Mark the tap centres on the front board at the derived spacing and height. Bore through from the outside with a backing block clamped behind. Drill the small probe passage near the top of the right board.
Hole saw or spade bit sized to your shank, drill/driver, clamp.
hole sawdrill bitdrill driverclampLine and finish the collar
Sand the edges and seal the outside of the timber. Cut the foam lining to the listed sizes, fit it inside the collar and cut the shank holes through it. Keep the top face of the collar smooth for the lid seal.
Sander and brush for the timber; ruler and utility knife for the foam.
sanderpaint brushrulerutility knifeFit the collar and move the lid
Clean the rim, stick the weatherstrip along it and run sealant beads beside it. Set the collar flush with the outside of the freezer. Unscrew the lid hinges, then fix them to the collar back board, or to the hinge blocks, at the same positions. Check the lid closes evenly all round.
Screwdriver or drill/driver with a driver bit. Two people lift the lid.
screwdriverdrill driverdriver bitFit taps, gas and controller
Fit the shanks and faucets, the drip tray on the freezer front and the gas manifold inside the collar. Set the cylinder and kegs where the model places them. Mount the temperature controller on the right board, run its probe inside and plug the freezer into it. Have a competent person check the electrical side.
Spanners for the shank nuts are not in the tool list. No holes go through the freezer walls.
Tools by operation
measure freezer
Measure the freezer outside, its wall thickness at the rim and the compressor step inside
mark collar
Mark the four collar boards square from the measured outer size
cut collar
Crosscut the front, back and side boards and the hinge blocks
join corners
Pre-drill and screw the butt corners, front and back boards over the side ends
bore shanks
Bore the shank holes through the front board and foam at the derived centres
line collar
Cut the foam lining to the derived sizes and fit it inside the collar
finish collar
Ease the edges and seal the outside of the timber; keep the top face smooth for the lid seal
fit collar and lid
Seal the collar to the rim, move the lid hinges onto the collar and check the lid closes evenly
Before you build
Check the lid weight on the moved hinges, the gasket seal, condensation on the collar, CO2 safety and ventilation, and the controller wiring, which a competent person does. The model sets no serving temperature or gas pressure.
- Check the lid weight on the moved hinges, the gasket seal, condensation on the collar, CO2 safety and ventilation, and the controller wiring, which a competent person does. The model sets no serving temperature or gas pressure.
- The freezer, its lid and hinges, the kegs, couplers, CO2 cylinder, regulator, manifold and controller are reference shapes for checking the fit; they are not cut or bought here. The freezer is drawn white with rounded corners, feet, a badge and lights; those are drawing details. Faucets, shanks and the drip tray are drawn shapes, not products. Gas and beer lines and the controller wiring are not drawn; the probe hangs on its lead.
- 5 kegs fit: 5 on the floor, with the CO2 cylinder on the step.
- A keg on the step would need 54 mm more collar height.
- The freezer sizes, hinge positions, foam and gasket thickness, tap spacing limits and the 10 mm gap around each keg are proposals. Measure your freezer and parts.
What the 3D model leaves out
The freezer, its lid and hinges, the kegs, couplers, CO2 cylinder, regulator, manifold and controller are reference shapes for checking the fit; they are not cut or bought here. The freezer is drawn white with rounded corners, feet, a badge and lights; those are drawing details. Faucets, shanks and the drip tray are drawn shapes, not products. Gas and beer lines and the controller wiring are not drawn; the probe hangs on its lead.
Taking the model apart separates parts for inspection; it is not an assembly order.
Dimension evidence and geometric checks
- keg
- 5 US gal ball-lock Cornelius keg, 8.5 × 24.75 in (Wikipedia, Cornelius keg). Measure yours.
- cylinder
- 5 lb aluminium CO2 cylinder, 5¼ × 17½ in as a supplier lists it; the listing does not say whether the valve is included.
- proposals
- Freezer sizes, wall and step, the 38 mm × 140 mm collar section, foam, gasket, shank hole, coupler clearance, hinge inset and every allowance below.
- allowances
- gasket
- 5
- handling Gap
- 10
- regulator
- 100
- shank Front
- 15
- shank Tail
- 40
- hole Edge
- 12
- minimum Tap Spacing
- 70
- hinge Block
- 120
- tap To Tray
- 250
- probe Hole
- 10
- id
- positive-dimensions
- ok
- Yes
- id
- kegs-under-lid
- ok
- Yes
- detail
- Keg plus coupler below the lid
- id
- cylinder-under-lid
- ok
- Yes
- id
- no-overlap
- ok
- Yes
- id
- collar-on-rim
- ok
- Yes
- detail
- Board plus foam 63 mm over a 70 mm wall; geometry only
- id
- stock-fit
- ok
- Yes
- id
- no-freezer-holes
- ok
- Yes
- detail
- Every hole goes through the collar or its lining
Reference renders
Fixed views of the original proposal. They do not change with your dimensions.
