Jockey Box 3.0
>> Monday, October 05, 2026
Equipment post! I ended up selling both of my previous jockey boxes (1.0 and 2.0) before we moved from Utah to Florida. The primary reasons were they were bulky and would take up too much space, and I figured they'd also get beat up traveling across country. I had one more brand new 54 quart Coleman cooler (same as 2.0) still in its original packaging, and I moved it with the intention of building a new jockey box at some point...and here it is.
This build is very similar to the previous two, but I figured I'd try to do a better job of documenting the process. A couple changes, I'm using EVABarrier tubing and Duotight/John Guest push connect style connectors. This should make it much easier to swap out tubing if/when the need arises. Hopefully it’ll also make maintenance a little easier, like blowing out the lines between uses. Due to the added resistance of the cold plate, I'm using 8mm x 5mm tubing on taps 1-3 instead of the typical 8mm x 4mm used on my Komos Kegerator. Tap 4 uses a section of 4mm ID tubing for some additional resistance since it only makes a single pass through the cold plate.
Parts
- (1) 54 quart Steel-belted Coleman cooler - I bought this on clearance at Sam's Club years ago.
- (1) Seven circuit plate chiller - This is a used soda cold plate I bought off eBay. I’ve mentioned it in my previous builds, these things aren’t cheap if you buy them new, but you can find used ones pretty cheap. Make sure they include the types of fittings you need for your build.
- (14) 5/16" Nylon flare washers - These are used between the cold plate and the cold plate fittings. If you're buying a used cold plate, replace them. If you're buying a new one, it should come with them.
- (4) Stainless beer faucets - Trust me, don't even mess around with plated brass; you’ll just have to replace them at some point. Buy once, cry once. I'm using three of my beloved original Vent-matic stainless faucets on this build, plus one Intertap.
- (4) 3" Stainless beer shanks - 2" shanks might also work, depending on how thick the walls and PVC caps are. My shanks are 316 stainless, but 304 is totally fine if there’s a price savings going with 304. In my case I lucked out and found some 316 shanks that were about half the price of 304s.
- (4) 1/4" MFL x 1/4" MFL Stainless fitting - These are used for the supply line bulkheads for the incoming beer.
- (4) 3/4" PVC caps - These are used to make the spacer for mounting the shanks.
- (18) 1/4" FFL x 5/16" Duotight/John Guest fittings - These are used to connect EVABarrier supply lines to plate chiller, jumping plate chiller circuits, etc.
- (4) 1/2" Beer thread x 5/16" Duotight/John Guest fittings. These replace the typical tailpiece used on standard beer shanks. These will allow me to connect EVABarrier tubing directly to the beer shank.
- 8mm EvaBarrier tubing - I used a combo of 5mm and 4mm ID tubing.
- (8) 7/16" Stainless washers - These are used on the supply line bulkheads (one inside, one outside).
- (4) Airborne containers - These are used to make the liquid bulkheads for the incoming lines. You could also use more PVC caps for this, but I’ve used the Airborne containers three times now and they work great. Combined with the stainless washers, it results in a very sturdy connection.
Preparing the Cooler
- Remove the Lid - Not absolutely necessary, but it'll make it easier and helps reduce the risk of damaging things.
- Remove Bottle Opener - Simply remove the three screws. In my 2.0 build, I mounted the right-most tap in this spot, so the flange covered the screw holes. This time I decided to mount the taps a little higher so the bottle opener was removed and the screws were screwed back into the existing holes to plug them.
- Make Holes for Taps - Height and position is mostly personal preference. I tend to like them high enough that I can fit a normal sized glass/cup under them. I measured down from the top edge of the cooler body. This is about 12.75 inches up from the bottom of the cooler. Standard spacing between taps is usually 2-3". If you want something more roomy, 3-4" could be used but anything over 4" is a little too much spacing. I have large hands so I went with a spacing of 3.25" between taps 1 and 2, as well as taps 3 and 4. Taps 2 and 3 are about 7 7/8" apart due to the latch and lid handle clearance. All these measurements are on center.
- I drilled small pilot holes from the outside of the cooler, all the way through the outer skin and the plastic liner.
- I then stepped the hole size up until the drill bit on my 1 3/8" hole saw fit through the hole (I believe it was 5/16").
- I then used my 1 3/8" hole saw on the inside of the cooler to make a hole in the plastic liner. Only drill deep enough to cut through the liner; not into the outer metal skin.
- Remove the foam insulation down to the metal skin. A flathead screw driver works well for this. A small plastic scraper or even a popsicle stick would also work well.
- Now use a 7/8" chassis punch to make a perfectly round burr-free hole. I would not recommend using a step bit here, just because the metal is fairly thin and I think it could deform trying to drill that large of a hole.
- You should now have a 7/8" hole through the metal skin, and a 1 3/8" hole through the plastic liner.
- Make the Holes for the Incoming Draft Lines - Same process as above with some minor differences. I use 1/4" flare fittings for the bulkheads. So instead of a 7/8" hole, I only need a 7/16" hole through the metal skin. On the backside, I need a 1.135" hole. I used a 1" hole saw and it ended up slightly over 1" in diameter. Additionally, I made these ~1.5" down from the top edge of the cooler, and about 1.25" from the edge of the carrying handles.
- Prep the Holes - Use some kind of paint to touch up any bare metal in the metal skin. Basically you just want to reduce the chance of rusting. I ordered a small bottle of appliance touch-up paint for this. It's easy to apply with its included brush, doesn't require you to mask off anything, it dries quick, and it's pretty durable. Here are a few pictures of the process:
Make the Bulkheads
In my opinion the bulkheads are one of the most important parts for a really clean DIY build. We need two different bulkheads. Fortunately they're easy to source and fabricate.
- Shank Bulkheads - I made these using 3/4 PVC caps. The outside diameter on these is 1.25" so they'll fit nicely inside the interior hole you made while also allowing a little bit of play for alignment. These caps will act as a spacer to prevent you from crushing and deforming the cooler when you mount the taps and tighten them down.
- Drill a 7/8" hole through the end of the cap. Some caps will have a casting mold mark that makes it easy to find the exact center. Mine didn't, so I drilled them as close as possible with a 1.25” spade bit, then cleaned it up a bit with my Dremel tool.
- Supply line Bulkheads - Like my previous two builds, I'm making these out of old Airborne tubes. They give you a really clean recessed type of fitting.
- Dry fit them into the hole on the inside of your cooler, and mark the depth on the tube. I like them to stick out about 1/8" so that the caulking has a place to bond to the tube when I do final assembly. Use the tool of your choice to trim them to length. I'm using my chop saw so that I get a nice even cut.
- Drill a hole in the bottom of the tubes. Just like the metal skin, I drilled them out to 7/16".
Install Bulkheads
Once your touch up paint has fully dried/cured, it's time to install the bulkheads. For the previous two builds I believe I used silicone and some epoxy to fix and seal the bulkheads. The epoxy didn't work all that great, but the silicone worked well. Earlier this year I had a slow leak in my pool's skimmer box and I used a product called 3M Marine Fast Cure 5200 to seal cracks. This product remains somewhat flexible but has very strong holding power, much stronger than silicone (it's considered a permanent adhesive) so I thought this would be a good use case for it. It's not food grade, but it won't be in direct contact with the beer, just the cooler and bulkheads.
Note: Fast Cure 5200 is messy and as I said it is intended to form a permanent bond between materials. Wear rubber gloves when applying and do your best to clean up any messes ASAP. It also moisture cures, meaning it uses humidity in the air to cure. You really want to use a tube of it in in one shot or you risk coming back to a fully cured tube.
- Install shank bulkheads - Mount the shank bulkheads with the drilled cap end facing the inside of the cooler. Apply caulk/sealant to the opposite end and carefully install the bulkhead into the hole. Do your best to make sure it's aligned with the holes and clean up any adhesive the squeezes out.
- Repeat for the remaining shank bulkheads.
- Next, I put a small bead where the edge of the bulkhead meets the hole you made on the inside of the cooler.
- Install supply line bulkheads - The process is basically the same here except we're mounting the bulkhead with the bottom of the tube against the inside of the metal skin. Sealant might squeeze out, so remember to clean it up while it's still wet.
- Just like the shank bulkheads, apply a small bead where the tube meets the cooler wall.
- Repeat for the remaining supply line bulkheads.
- Leave all the bulkheads to cure for 24 hours. Note: I used a couple fender washers, a 2" machine screw, and a nut to hold the bulkheads in place while they cured (~24 hours). Masking tape might also work. You just want to make sure they don't shift out of position before they've cured.
Cold Plate Rebuild
All the cold plates I've used have 5/16" FFL fittings, but double check yours to make sure it's not 1/4" as I've read that some can be. The cold plate consists of circuits of stainless tubing embedded in a cast aluminum block. Some have 1/4" MFL x 5/16" MFL fittings, but some have 1/4" barbed x 5/16" MFL fittings...or in my case, could have a mix of the two. If you're going to use EVABarrier tubing and push connect fittings, you'll need to replace any barbed fittings. After dealing with the pain of replacing all the lines on Jockey Box 2.0 before selling it, I can tell you barbed fittings kind of suck. You're dealing with limited clearance between fittings, so just removing a step-less clamp is a total pain. After using them on my Komos kegorator, I decided to try using Duotight fittings for this build. These push connect fittings make it a much easier job when it comes to replacing tubing.
Note: I used a mix of John Guest and Duotight because I got a really good deal on the John Guest fittings. However, two of them ended up leaking and were replaced with Duotight. From what I could see, Duotight appear to have two o-rings whereas John Guest have a single o-ring.
- If needed, start off cleaning off any dirt or grime that you find on the outside of the cold plate.
- Next, remove all the flare fittings from the plate chiller.
- Remove the old flare washers from the plate chiller. They will often just fall out if you turn the chiller upside down. If not, a small pick tool should help retrieving them.
- Install the Duotight/John Guest fittings onto the 1/4" MFL x 5/16" MFL fittings you just removed. Clearance can get pretty tight with the cold plate, so it's usually easier to do this before reinstalling fittings. Make sure they're tight, but don't overtighten and risk stripping the threads.
- Install new flare washers into cold plate. Make sure they're not flipped upside down.
- Install the stainless flare fitting with the push connect fitting into the cold plate. I usually start at one end and work my way across. A crows foot wrench on a ratchet works well.
- Install circuit jumpers. Since I'm using a 7 circuit plate but only have 4 taps, I jump taps 1-3 to make a double pass, and tap 4 does a single pass.
- Tap 1 - Uses circuits 1 and 6
- Tap 2 - Uses circuits 2 and 7
- Tap 3 - Uses circuits 3 and 5
- Tap 4 - Uses circuit 4 (single pass)
- After assembly is complete, clean your plate chiller by recirculating BLC. I do this after final assembly.
Cold Plate Stand
The last thing to build is the Cold Plate Stand. You don't have to build one of these, but if you travel with your jockey box it keeps the very heavy cold plate from sliding around inside the cooler. It also keeps the cold plate slightly elevated above the bottom of the cooler, out of the meltwater.
Since the dimensions of cold plates can vary, I'm not including measurements for my build, but I've included pictures for reference. I used 1/2" PVC pipe and four 1/2 PVC cross tees to make a box and the cold plate sits on top of it. The bottom of most cold plates have a feet that are part of the aluminum casting. I try to make it so the inside dimensions of the box basically match the outer dimensions of the feet. Then I attach the cold plate to the stand using large zip ties. The pieces of PVC pipe extending beyond the box are sized to fit snugly in the cooler. The end result is neither the stand or the cold plate can shift more than a quarter inch or so.
Final Assembly
Final assembly is pretty straightforward. If you've ever put together a keezer or kegorator, it's petty much the same, just a few extra plumbing connections.
- Install the 1/4 flare fittings into their bulkheads and secure with the appropriate stainless nut.
- Install the stand and cold plate.
- Install shanks and secure with the shank nut.
- Install tailpieces.
- Make draft line connections inside the jockey box.
- Make the draft line connections for the outside of the jockey box (ball-lock disconnects --> tubing --> swivel nuts. Notice, I'm not using push connect fittings on the outside of the jockey box.
- Reinstall the cooler lid.
The last thing to do is pressure test all circuits. In my case I keep a 5 gallon keg of StarSan that I use for sanitizing and purging kegs. This works great for pressure testing as it allows you to check one tap at a time and watch for leaks. I ended up pressurizing each line to about 25 psi for 10-15 minutes while watching for leaks. I had a couple that were caused by the push connect fitting not being screwed down tight enough on their respective 1/4 flare fitting, but as I mentioned above, I also had two of the JG fittings that seeped around the tubing.
After you’ve pressure tested everything, the next thing to do is to try it out. For cold plate jockey boxes, you want minimum water in the cooler. This is different than cooling coil jockey boxes where water will typically improve the cooling. So, fill the cooler with ice, then drain off water and replace ice as needed. That’s about all there is to it. Below are a few more pics I took during the build process.
Airborne bulkhead
Test fitting Airborne
Another view Airborne
Shank caps in place
Airborne sealed and caulked
Shanks sealed and caulked
Test fitting cold plate
Incoming line bulkheads
Starting to plumb lines
Interior all plumbed
Ready for leak testing
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