
Kettle Insulation: DIY
Craft Hardware no longer sells kettle insulation, but you can easily make it yourself with a few simple tools. The end result is without the polyester outer sheath, but looks aren't everything: the insulation is, of course, the most important part of the set.
At the bottom of this page, you will find the insulation templates you need to cut your insulation.
Required material:
- A polyethylene foam sheet. I recommend Plastazote LD29 PE foam, for example. Be careful not to choose the version with adhesive back! Recommended thickness: 10 mm for easy handling. 15 mm for better insulation, but it is quite frustrating to attach and remove the Tri-Clamp clamps. You need a long sheet, which can be found in the standard size of 2 m x 1 m. For 40L and 60L kettles, you can get two pieces per sheet, for the 85L and 115L size, only one. Possible suppliers:
- Adam Hall 019310 Plastazote LD29 PE Schaumstoff 10 mm
- Wikotech-Beschlaghandel 10 mm Plastazote PE-Schaumstoff (LD29)
- Straps to secure the insulation to your kettle. I recommend 4 straps, as sold in the shop BIAB Spannriemen – Craft Hardware but you can also get your own elsewhere.
Tools Required:
- cardboard knife with sharp blade
- marking pen, preferably silver or white. A blue ballpoint pen can also be used, but is harder to see.
- Long ruler or measuring tape
- long straightedge as a cutting aid
- HT Bogen DN40 90 grad (as a hole punch for the TC nozzles)
- A short piece of Stangenrohr / Kabelschutzrohr EN 20 (as a hole punch for the boiler handles)
- HT Bogen DN50 90 grad (as a hole punch for the optional ring heating element)
Instructions
Find a large, open space to work in that will not be damaged when cutting the foam. A large wooden workbench or a tiled basement floor may be suitable. Be careful with the utility knife and wear protective gloves.
You can find the PDF links for the Craft Hardware kettle insulation templates below.
Schritt |
Bild |
1. Cut out the rectangle for your kettle using the kettle template meaurements. Use a straightedge to help you make a clean, straight cut. | ![]() |
2. Mark the center of the standard ferrules (shown in green in the drawing). |
![]() |
3. Mark the center of the kettle's handle holes (shown in orange). Punch the kettle handle holes using the short piece of 20mm plastic pipe. Push and twist it to get through the foam. |
![]() |
4. Punch the holes for the Tri-Clamp ferrules with the DN40 elbow. Push and twist the DN40 elbow to get through the foam. |
![]() |
5. Use the box cutter to cut a slot between the handle holes to allow the insulation to fit over the kettle's front handle. |
![]() |
6. Use the box cutter to cut from the center of the 20 mm large handle holes on the left and right side of the insulation to the edge of the insulation. This allows the insulation to be routed over the rear handle. |
![]() |
7. Optional. Mark and punch the holes for the HERMS spiral or the ring heating element. The ring heating element should be punched with a DN50 pipe. |
|
8. Attach the insulation to the kettle. Start at the front and slide the insulation over the kettle handle and the front Tri-Clamp ferrule. Then wrap the insulation around the kettle and slide it over the remaining Tri-Clamp ferrules. The insulation should converge flush at the back of the kettle. Attach the straps. |
![]() |
The instructions do not include dimensions for the lid insulation because it is very difficult to cut cleanly. If you have some leftover material and want to try it out, you can use your lid as a form and carefully cut around it with the box knife. Place the lid flat on the insulation and cut as close as possible to the inner lip of the lid (the smaller diameter). Then measure out the position in the lid for the handle holes and cut them out accordingly (20 mm).
It is normal for the insulation to shrink a little after first use. This is normal and it will expand again when heated.
Note: Please recycle any leftover polythene foam. This is usually treated the same as normal packaging material, but please check with your local waste disposal company to see if it can be put in the plastic recycling bin.
Craft Hardware Kettle Templates |
40L Bottom Drain |
60L Bottom Drain |
85L Bottom Drain |
115L Bottom Drain |
38L Flat Bottom |
57L Flat Bottom |
83L Flat Bottom |
114L Flat Bottom |