This section is from the book "The London Art Of Cookery and Domestic Housekeepers' Complete Assistant", by John Farley. Also available from Amazon: The London Art of Cookery.
The copper-work, in process of time, like every thing else, will become defective; and when this is the case, the following very simple remedy will make the parts as perfect as ever: work the penstaff in the brass socket with emery and water, or oil, which will make it perhaps more perfect than when new, and many instances have been seen of this method being used with cocks just purchased.
It would be no inconsiderable addition to the conveniency of the under back, to have a piece of copper to line the whole in the bottom, which may be stopped with a cloth put singly round a large cork; and when it is fastened down for the wort to run, it will be necessary to put a large weight on the cork, which will prevent its flying up by the heat. When the liquor is pumped clean out of the back, the cloth round the cork will enable you to take out the cork with ease; and there should be a drain below the under back to carry off the water, which will enable you to wash it perfectly clean with very little trouble. This drain should be made with a clear descent, so that no damp may remain under the back. With the convenience of water running into your copper, you may be enabled to work that water in a double quantity, your under back being filled by the means of letting it in at your leisure, out of your copper, through a shoot to the mash-tub, and so to the under back. Thus you will have a reserve against the time you wish to fill your copper, which may be completed in a few minutes, by pumping while the upper cock is running. Thus much for the principal utensils in brewing; but be careful to keep every thing perfectly clean.
As we have now properly explained the precautions necessary to be taken in the preparation of vessels, we shall enter into a concise detail of what is to be observed in the course of brewing.
Having your utensils scalded, your malt ground, your copper boiling, and your penstaff well set, you must then proceed to mash, by letting a sufficient quantity of boiling water into your tub, in which it must stand until the greater part of the steam is gone off, or until you can see your own shadow in it. It will then be necessary that one person should pour the malt gently in, while another is carefully stirring it; for it is as necessary that as much care should be observed when the mash is thin as when it is thick. This being effectually and well done, and having a sufficient reserve of malt to cover the mash, to prevent evaporation, you may cover your tub with sacks, etc. and leave your malt three hours to steep.
Previous to your letting the mash run, you should not fail to be prepared with a pail to catch the first flush, as that is generally thickish ; and another pail being applied while you return the first on the mash, and so on for two or three times, or at least until it run fine. By this time your copper should be boiling, and a convenient tub placed close to your mash-tub ; let into it through your spout half the quantity of boiling water you mean to use for drawing off* your best wort. After this, you must instantly turn your cock to fill up again, which will boil in due time with cinders or coal-ashes. During such time, you must stop the mash with this hot water out of the convenient tub, in moderate quantities, every eight or ten minutes, until the whole is consumed; then letting off the remaining quantity, which will be boiling hot, to the finishing purpose for strong beer.
You must then fill your copper quite full, so as to boil quickly for the second mash, whether you intend it for ale or small beer. Being thus far prepared, let off the remaining quantity of water into the tub, as you did for the strong beer, stopped up as before; but if you would have small beer besides, you must judge it accordingly, by boiling a proper quantity off in due time, and letting it into the tub as before. It is better to avoid the latter article, that you may entirely draw out the strength for the ale.
Twenty-four bushels of malt will make two hogsheads of as good strong beer as any in England, and also two hogs-heads of very pretty ale, but the malt should consist of equal portions of brown, amber, and pale. This strong beer should be kept two or three years, and the ale never less than one, before tapped. If your mash be only for one hogshead, it should be two hours in running off; if for two hogsheads, two hours and a half; and for any greater quantity, three hours: for there is no good in letting it be too long, as the whole strength is extracted by the frequent stoppings.
You must be particular in the time of steeping your mashes. Strong beer must be allowed three hours; ale one hour; and, if you draw small beer after, half an hour. By this mode of proceeding, your boilings will regularly take place of each other, which will expedite the business, by prevent-ing loss of time. Be particularly careful, in the course of each mashing, that it be thoroughly stirred from the bottom, and especially round the muck basket; for, being well shaken, it prevents a stagnation of the whole body of the mash; and were this last process omitted, it would certainly fox your beer, and give it an exceeding bad taste.
In preparing for boiling, be particularly careful to put the hops in with the first wort, or it will char in a few minutes. As soon as the copper is full enough, a good fire should be made under it; but be careful, in filling it, to leave room enough for boiling. Quick boiling is one of the most necessary things to be observed ; though in this particular there are variety of opinions. However, there is perhaps but one good method, and that is quick boiling. Great caution should be observed when it begins to swell in waves in the copper; if you have no assistant, be particularly attentive to its motions; and being provided with an iron rod of a proper length, crooked at one end, and jagged at the other, then with the crook you are enabled to open the furnace, or copper door, and with the other end push in the damper, without stirring from your station ; but on the approach of the first swell, you will have sufficient time to proportionate your fire, as care should be taken that it be not too predominant. When the boil is properly got under, you may then add a fire that will boil briskly, and there may be a variation of a few minutes.
 
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