Cut the pipe
Use a tubing cutter to cut the legs (A), base support (B), top spacers (C) and bottom spacers (D) out of 1/2-in. copper pipe according to the cut list above. Sand back any sharp edges or burrs on the cut ends with sandpaper and a metal file.
Dry fit the copper fittings
To ensure every measurement works and the frame comes together as you wish, dry-fit the cut legs (A), base support (B), top spacers (C), and bottom spacers (D) with the 90-degree elbows (E) and three-way couplers (F) to create the frame. Dry-fitting allows you to make adjustments as needed before gluing the fittings together.
Prepare the connections for glue
After confirming that the pipe couplings are the right size and fit, disassemble the dry-fit pieces and prepare them to be glued together with CA glue. Use 320-grit sandpaper to scuff the outer ends of each pipe piece and a 1/2-in. pipe wire brush to scuff the inside of each pipe coupling. Scuffing with sandpaper and a wire brush will give the copper surface “teeth” or a place for the CA glue to grab onto. For a clean appearance, only scuff the last 1/2-inch on each end of the pipe.
Glue together the frame
As you secure the copper pipe to the elbows and couplers with CA glue, utilize a Speed Square to ensure the frame is square. Hold it square with 90-degree corner clamping jigs while gluing. Use quick-grip clamps to prevent pieces from moving until they dry. When you reach the top section, use a level to ensure the frame is level from front to back and side to side before gluing.
Glue the joints strategically. The medium viscosity of CA glue will run downward into the joint, keeping the seams clean and preventing glue from dripping down the pipe. Position the frame in a way that will minimize mess when applying glue.
Cut the copper cone for the funnel
Start with a six-inch pre-cut copper circle. Cut out the “C” shape as shown in Figure A. The template was designed specifically for the glass funnel we will be using. Create a funnel template from paper if you are using a different glass funnel, so that you can test its dimensions and ensure that the funnel fits well.
After filing back the jagged edges of the cut, make a 1/2-inch fold in one end of the copper “C” and hammer it so it lies flat. This prevents an exposed sharp edge on the outside of the funnel. To close the funnel, slowly form the copper “C” into a cone until the ends overlap. The folded-over end will lie outside the other flat end of the copper cone.
Rivet the funnel together
Use a quick-grip clamp to hold the formed funnel in place while you drill through both ends. A one-inch dowel can help provide a surface to drill against and serve as a guide to maintain the correct opening at the bottom of the funnel while riveting it.
Using a 1/8-inch drill bit, drill holes through both ends of the copper “C” formed into a funnel for 1/8-inch rivets. Ensure the flaps of the funnel stay in place while drilling so that the holes align. Insert a rivet into the drilled holes and set it with a 1/8-inch riveter. Once you have secured one rivet, proceed by pre-drilling evenly spaced 1/8-inch holes for additional rivets. Install the remaining rivets until the funnel form has been secured.
Solder on the funnel neck
Use crumpled-up aluminum foil to create a mold that will hold the 1-in. x 1-1/2-in. copper pipe for the funnel neck and the riveted funnel cone in place as you solder the two pieces together. It should be positioned so that when the funnel is soldered, the glass funnel will protrude slightly from the bottom of the copper funnel. Apply flux to the entire seam. Slowly heat the copper pipe and funnel cone with a propane torch to evenly heat the copper as you solder the two pieces together.
Clean and polish
Clean up any flux residue on the soldered funnel and pipe with soap and water. You can polish copper organically by applying ketchup with a rag and cleaning it with soap and water afterwards.
Assemble and make coffee
Insert the borosilicate glass funnel into the copper funnel and set them in the top opening of the copper frame. Fit a 5-1/2-inch wide scrap piece of solid surface countertop, a cutting board, or a 1×6 under the funnel. Now you are ready to make coffee!
Health and Safety Note: When making your coffee with this pour-over, ensure that the coffee does not come into contact with any copper.
FAQ
Which kind of filter is best for the pour-over coffee maker?
It is recommended to use paper coffee filters with your pour-over coffee maker. Paper filters allow all the nuanced flavor of your coffee to come through.
What is the best temperature for brewing coffee?
According to the National Coffee Association, the ideal water temperature for extracting flavor from a coffee bean is between 195°F and 205°F. The lower temperature range (195°F) is better suited for dark roasts and helps prevent bitterness. The higher temperature range, 205°F, is recommended for a lighter roast to prevent sourness in your extraction.
Why use a borosilicate glass funnel with a pour-over coffee maker?
Borosilicate glass is designed to withstand high temperatures safely. Regular glass may crack and break with exposed to extreme temperatures. Like wanting oven-safe glassware. Pyrex is a name brand of borosilicate glass.
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