On the inside I used a orange silicone o-ring then a stainless washer then the standard nut that comes with the mashmaster thermo.
As there's no flare on the thread they tend to leak through the thread. I got around this by wrapping a ridiculous amount of thread tape around the thread where the nut would sit when it was tightened. So much thread tape that it was built up more than the thread.
If you're going through the wall of a cooler I would drill your hole, pick out about 15mm of insulation from within the wall and fill that space with Sealey's Knead-it which is food safe. The wall of the cooler is too soft when hot to be tightened up enough.
Not too sure what you mean on the last bit. If you're talking about the inside of the valve itself it's as I bought it. I've disassembled them after 15+ brews and the internal seals are fine (couldn't say the same about the rubber over the handles though). If you're talking about getting through the wall of the kettle - same as for the thermos.
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