I just started to build my mash tun. I bought a 48qt Coleman cooler and some 1/2 copper tubing, elbows and tees. I used a 1/2 threaded ball valve and it's connected to a 1/2 PVC threaded piece on the inside. Here are some pics:
I need to get some more soft copper for the sparging arm which I'll mount to the lid of the cooler. I'll work on that later this week.
Looks good there Paul. How is everything held together? I tried a copper manifold and the first time I stirred my mash I knocked it apart. I got a stuck sparge and had to dump it in a bucket and put the braid back in. Never went back after that. I've seen a lot of people have luck with copper though. Maybe some stainless screws in the joints so you can take them apart to clean.
I don't think I'm going to sweat the connections for the manifold, but I will when I create the sparging arm. The small screws might work if I have problems with it coming apart. It is pretty tight fitting tho.