220gal Plywood/steel hybrid. Pull up a chair, this will take a while.

Steve,
Loving this thread! I feel your frustration with weld shrinkage.

I just dropped a bunch of coin :eek1: on an Aluminum MIG setup with the push - pull gun. My dad is an expert welder so he gave me some great tricks, but boy you fight the warpage!! Was awesome learning a new skill though. Aluminum stand here I come:)

What epoxy adhesive filler are you referring to? I have always used glass microspheres, is yours a chemical additive?

Thanks,
Chris
 
Chris,
406 Colloidal Silica
406 Colloidal Silica is a thickening additive used to control the viscosity of the epoxy and prevent epoxy runoff in vertical and overhead joints. 406 is a very strong filler that creates a smooth mixture, ideal for general bonding and filleting. It is also our most versatile filler. Often used in combination with other fillers, it can be used to improve the improve strength, abrasion resistance, and consistency of fairing compounds, resulting in a tougher, smoother surface. Color: off-white.
Click to expand...

I already had it on hand and it is rated 4 out of 5 stars for hardware attachments.

West system does have another additive that is rated 5 stars. I think it is the 404 High-Density Filler.
404 High-Density Filler
404 High-Density filler is a thickening additive developed for maximum physical properties in hardware bonding where high-cyclic loads are anticipated. It can also be used for filleting and gap filling where maximum strength is necessary. Color: off-white.
Click to expand...

Like I said, I already had the 406. But If I didn't I would have used the 404.


As far as updates, I have been working on some details. Adding a 2nd wavebox compartment and there will be some integrated plumbing and wire chase.

You can see the hole in the right rear corner. I will have some more pics later on.
DSCN4570.jpg



http://www.westsystem.com/
 
Here is a pic of the 2nd wavebox chamber and the plumbing/wire chase.
DSCN4575.jpg


And a closeup. That is a 4" pipe for wires and two 1-1/2" for returns.
DSCN4576.jpg



Initially, I wanted to move the wavebox towards the back of the tank to keep the front as "clean" as I could. But on more consideration, I might need it towards the front after things grow. They say you get the best results if the wavebox has a clear shot to the opposite wall. Or... I could just ad a 2nd wavebox :lol:
 
Man this design keeps getting better and better. I would like to see some images from the left side and left rear corner please.

Or has that been inverted? Difficult to tell
 
I see your frame is welded, but I'm wondering how your actually screwing all the pieces together with them sitting in the frame already?
 
What size screws are you using to connect the front of the wavebox and such? I see they are "rabbited" and predrilled and countersunk holes?
 
The screws are 1-5/8 deck screws. I did not splurge for the stainless ones, but these are coated with some sort of stuff.

The tank is on its back and we are looking right into the top of the tank in the photo above, nothing has been inverted. But, the overflow is not installed yet.

More pics to come.
 
Shaping up Steve, looks great so far, like the idea of the internal plumbing/wire chase and glad you made it big. ;)

Are you having a time moving it around, or is it still light weight enough? Do you have an estimate as to what it will weigh once it ready?

DON'T THROW YOUR BACK OUT NOW:rolleyes:
 
Not too bad now. Probably 150 lbs. Maybe a little less. What does 6 gal of epoxy weigh? Add that to it and that will be the weight before the glass.


I will be flopping it around a whole bunch, as I am going to use the pour method when applying the epoxy. After the initial coat with fiberglass, I will have a 3/16" or so thick, solid epoxy layer. Then the epoxy paint.
 
Looking very good!!!!! Couple of questions....what are the dimensions of the upright pieces there on the left front of the tank? How much of a lip are you planning on the front viewing area on top and bottom to seal your glass into place?
 
The upright on the left is 1/8x1x1 angle, but it measures more like 7/8. on the outside edges, and 3/4 on the inside. I would hav gone smaller, but could not find it locally.

I ended up with 2" angle all around the perimeter of the front glass, with the exception of the top of the end panel. There the angle is 1-1/2.

I will have about 1-1/4" of lip supporting the glass.
 
3d Puzzle is about right!. :lol:


Funny you should ask about the cane stripping?? I worked on that a little bit today.

I have some oak I have cut down to about 1-1/4" on each side - and a 45 across the face. This will go along the back wall and the short section for the plumbing/wire chase.

The short side where the overflow/waveboxes are probably won't get it. They don't really need it because the vertical piece is fully restrained on both sides in a dado, where as the piece along the back only has support on one side in the rabbit.

I might get them in place tomorrow.
 
Looking good !!!! I'm been following intently and love the work.....started my woody saturday and hope you don't mind copying alot of your ideas......working on the 45's as well......Do you think there will be an issue with getting the epoxy down inside to coat your metal framing easily? I'm also using the metal framing method even though I was told it wasn't necessary, but thought about when routing out the channel to fit around the angle possibly cutting a shallow "V" grove to allow the epoxy to really flow through the area!!!!! Any thoughts???? Still tossing around ideas for bracing across the top due to the 42" width of the tank......
 
Chris,

I think I have adequate coverage of the angle in the groove.

<a href=showthread.php?s=&postid=13575339#post13575339 target=_blank>Originally posted</a> by AcroSteve
I had drilled some 1/2" holes every 6" so I could pour the epoxy into the groove I had cut for the angle iron. I am pretty confident that I filled all the space with either angle or epoxy. The epoxy was thickened with some adhesive additive, that's why it is whitish.
DSCN4571.jpg


Click to expand...

The internal dimensions of the overflow box are 5-1/2 x17. And the trough along the back is 2x4 on the shallow end and it slopes down to 2x7.

Here are a few more pics.

DSCN4625.jpg



DSCN4627.jpg



DSCN4628.jpg
 
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