While pondering some repairs for his Gaggia Classic Pro espresso machine, [Hans Gaensbauer] ended up machining an entirely new boiler from stainless steel.

It was a nontrivial undertaking, since the boiler is an assembly that integrates not only heaters and pump connections, but one end is also the group head into which the portafilter interfaces. [Hans] had to deal with machining out the contours and pockets necessary for a portafilter to lock in securely, complete with the little screen and perforated plate responsible for even water distribution. And of course, the whole thing still has to fit into the original machine. All in all, [Hans] had some constraints to work around, making it a considerably more complex job than just milling a chamber out of a block of stainless steel.

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