Encapsulated heating element fluid heater

A method for assembling an encapsulated heating element fluid heater fluid heater, comprising the acts of:

• providing a vessel being generally cylindrical and having an end, said end of said vessel having an opening therein, said end of said vessel having a beveled weld edge;
• providing an end cap having first and second ends, said end cap having a plurality of bores therethrough extending between said first and second ends of said end cap, said first end of said end cap having a beveled edge, said end cap having a plurality of elongate heating element rods extending through said bores of said end cap, said heating element rods having a heating portions outwardly extending from said first end of said end cap, said heating element rods having electric coupling portions outwardly extending from said second end of said end cap, each of said bores of said end cap having a seal therein for substantially sealing each of said bores of end cap to prevent passage of fluid through said bores of said end cap, said seals comprising an epoxy;
• inserting said first end of said end cap into said opening of said end of said vessel such that said heating portions of said heating elements extend into said vessel, said beveled weld edge of said end cap being positioned adjacent said beveled weld edge of said end of said vessel;
• providing a chill bar comprising a base and a cap member, said base being generally cylindrical and having first and second faces, said first face of said base having cavity therein, said cavity being generally cylindrical and having a diameter and a circumference, said base having a pair of elongate bolt holes extending therethrough between said first and second faces of said base, said base having a pair of fluid passages extending between said second face of said base and said cavity of said base, said fluid passages being positioned adjacent said circumference of said cavity of said base, said fluid passages being for fluidly connecting said cavity of said base to a coolant fluid reservoir, said cap member having a cover portion and an insertion portion, said cover portion of said cap member being generally disk-shaped and having first and second faces, said insertion portion of said cap member being generally cylindrical and having a diameter and a circumference, said insertion portion of said cap member being outwardly extended from said second face of said cover portion of said cap member, said diameter of said insertion portion of said cap member being less than said diameter of said cavity of said base, said first face of said cover portion of said cap member having a circular depression therein, said first face of said cover portion of said cap member having a plurality of spaced apart receiving bores therein extending through said cover portion of said cap member and into said insertion portion of said cap member, said receiving bores of said first face of said cover portion of said cap member being positioned in said depression of said first face of said cover portion of said cap member, said second face of said cover portion of said cap member having an annular ridge around said circumference of said insertion portion of said cap member, said ridge of said second face of said cover portion of said cap member having an outer circumference, said cover portion of said cap member having a pair of retainer holes therethrough between said first and second faces of said cover portion of said cap member, said insertion portion of said cap member being inserted into said cavity of first face of said base such that an annular cooling space is defined between said circumference of said cavity of said base and said circumference of said insertion member of said cavity, said second face of said cover portion of said cap member abutting said first face of said base such that said ridge of said second face of said cover portion of said cap member is inserted into said cavity of said first face of said base, one of said retaining holes of said cover portion of said base being coaxially aligned with one of said bolt holes of said base, another of said retaining holes of said cover portion of said base being coaxially aligned with another of said bolt holes of said base, a retaining bolt being extended through each pair of associated retaining and bolt holes to couple said cap member to said base;
• inserting said electric coupling portions of said heating element rods into said receiving bores of said cap member of said chill bar such that each electric coupling portion is inserted into an associated receiving hole;
• abutting said first face of said cover portion of said cap member of said chill bar against said second end of end cap such that said second end of said end cap is inserted into said depression of said first face of said cover portion of said cap member of said chill bar;
• circulating coolant fluid through said cooling space of said chill bar such that said seals in said bores of said end cap are maintained at a temperature below a predetermined temperature, wherein said predetermined temperature is about 160 degrees Fahrenheit;
• and
• welding said beveled weld edge of said end of said vessel to said beveled weld edge of said first end of said end cap to couple said end cap to said end of said vessel.