I just used a drill bit to cut out the hole, the hole was not perfect but it works with no leaks.

How big is the current hole? I've got 2 batches fermenting myself or I'd check. I've found a 1" diameter spigot here:
http://www.midwestsupplies.com/products/ProdByID.aspx?ProdID=7819

It uses 1/2" hose though.

Going with a 1 inch hole saw (sounds about right) ??? You might want to ask Poodie about his experience if I'm not mistaken. You would need to have some kind of "backing".

When I bought my new nozzles, the dude at the LHBS claimed they were 7/8's (he was wrong ) Trust me the one's Monty has illustrated are 1 inch.

Just my .02

Just to verify,spigot is 1" hole and 3/8" OD nozzle. The grinder wheel(Lawn Mower Blade Sharpener) that goes in the drill is about a buck at any hardware store. I looked at the 1" hole saw idea, but mine was 7/8" and I didn't see an easy way to center the cut.

Monty

Small hunk'o'wood on the inside that you can put flat against the inside of the keg. It will make a better cut too since you have something bracing the plastic while it is being cut.

And here I thought I wqas special for doing this to mine a while back.
I picked up a spiggot from my local shop so that I could use my bottling wand to fill the bottles.

This is the one mod that I think everyone should do if they make more than one batch every couple of months. With a spiggot that has a standard OD to the higher end gear you get more options for things to try. I even use the spiggot and hose to rack mine to a secondary... no need for a racking cane (my secondary has a spiggot too).

Wow. What a cool idea, I wish Mr Beer would do something like that. Im afraid I would screw up my keg if I altered it. On my last batch mine started to leak so I just ordered a new one

Fermenter 1:American Classic
Carbonating:nuttin
Lagering:nuttin
Drinking:nuttin
PS New kid on the block never done something like this before gald to find some brewers who use the same thing I do

Welcome TX Brewer to the keg! Lots of info and good folks here. Ask questions or search the posts for the answer. Sometimes the threads get a bit off track but you get to know the personalities here that way.

Welcome to our obsession Tx Brewer.

Yeah we've been known to turn the train into an all terrain vehicle on occasion but more often than not your questions will be answered and you may find a little humor along the way.

Here's the spigot I used:

http://www.usplastic.com/catalog/product...duct%5Fid=16264