Current Stage: Complete

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Design:

Tub:

Grizzly 400 cooler with one hole drilled into the side for a bulkhead fitting & chilled water inlet. I like the fact that the cooler is well insulated. This should ensure the chiller doesn't have to work very hard. The size is great. I think this cooler is going to get popular for cold plunge builders.

Chiller:

1/4HP chiller should be plenty powerful for this. The cooler is well insulated and I'm keeping it in my insulated garage. Hottest recorded garage temps have been 92F in peak summer with 100+ degree temps. I also have the option of adding ice if I want extra low temps.

Filter:

I'm using a bigger 4.5 x 10 whole home filter to help increase my flow rate. The larger filter will also ensure it doesn't need to be cleaned as often. I spent the extra money on a clear housing so I can see how dirty it's getting.

High Flow Rate:

I'm going to try to use as few fittings as possible to help achieve high flow rate, hopefully no tees or elbows. I will measure flow rate.

Tubing:

3/4" Flexible PVC tubing will be used. This will be very convenient.

Pump:

A 1200GPH pump is in range for the chiller and hopefully I can keep the final flow rate high. I will measure flow rate.

Sanitation:

H202

Parts List:

Note: I do not endorse or have any affiliation with the sellers listed below. You can find these parts many places.

Cooler
- Grizzly 400: $1,231.42
- Grizzly Torrent Twist™ Plug with Hose Connection: $18.80
Chiller
- Active Aqua 1/4 HP : $612.64
Pump
- Danner Mag-Drive 12 1200 GPH: $124
Bulkhead
- I am now recommending this bulkhead fitting: https://www.mcmaster.com/36895K122/
- FlexPvC also sells a bulkhead that will work: Custom Bulkhead Fitting 3/4” fpt x 2” WALL
Filter Housing setup
- Pentek 10" Big Clear Filter Housing with 1" Ports and Pressure Release: $138
- Housing Bracket (included above)
- Sediment Filter: Harmsco Calypso Blue 20 Micron Pleated Sediment Cartridge: $25
Tubing
- FlexPvc 15 feet: $50 (I ended up using 10 feet.)
Fittings
- You might need to add a few fittings, like an elbow, depending on where you chiller sits relative to the cooler.
- I ordered more unions than I needed just in case. They are way cheaper than local.
- Cost of fittings: $37

Filter Housing connections:
- 2 x 1" male MPT to 3/4" male MPT nipple
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Nipples-Reducing-TBE&p_id=8303-131&xm=on&ppinc=detail
- 2 x 3/4 FPT Union
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Unions-China&p_id=1207GT&xm=on&ppinc=detail
Bulkhead connections:
- 3/4 MPT x 3/4 MPT (bulkhead external tub to union)
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Nipples-Poly-Nylon&p_id=TN51212&xm=on&ppinc=detail
- 1 x 3/4 FPT Union
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Unions-China&p_id=1207GT&xm=on&ppinc=detail
- 1 x 3/4 MPT to male hose (To drain the tub or do flowrate test etc. Threads into bulkhead inside tub)
  - https://flexpvc.com/cart/agora.cgi?p=GardenHose-Male&p_id=16-010&xm=on&ppinc=detail
Chiller connections:
- 2 x 1.25 female adapter
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-FemaleAdapters&p_id=435-012S&xm=on&ppinc=detail
- 2 x 1.25 to 3/4 reducer bushing
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Reducer-Bushings-Slip-Spg&p_id=437-167S&xm=on&ppinc=detail
Pump connections
- 1 x 3/4 FPT to 3/4 male Spigot
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Female-Adapter-Spigot&p_id=478-007&xm=on&ppinc=detail
- 1 x 3/4 MPT to 3/4 Spigot
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Male-Fitting-Adapters&p_id=433-007&xm=on&ppinc=detail
Tub Drain connection
- 1 x Hose to 3/4 slip fit
  - https://flexpvc.com/cart/agora.cgi?p=GardenHose-Female&p_id=F-66-P&xm=on&ppinc=detail
Hose connections ( 4 hose segments total)
- 7 x 3/4 union slip fit
  - https://flexpvc.com/cart/agora.cgi?p=PVC-Fittings-Unions-China&p_id=1207GS&xm=on&ppinc=detail
Pipe Thread Sealant ( Whatever is at local hardware store)
PVC Primer and Glue ( Whatever is at local hardware store)
Tubing insulation ( Whatever is at local hardware store)
3/4" PVC pipe. You won't need much, but you'll probably have to buy one long piece. You'll need some way to cut this.

Technical Notes:

Hole saw bit size: FlexPVC bulkhead: 1 3/8" . McMaster Bulkhead: 1 5/8"
Flow rate:
- Without Filter: ~8-9 GPM
- With 20 micron filter: ~5-6 GPM
Energy usage and cost:
- Chiller and pump are switched ON 24/7
- Energy cost: $0.14/kWh
- Chiller: With garage temp at 82-84F ~$9.20 per month.
- Pump: $6.85 per month.