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

[AcroSteve]

Yea, this is just regular birch plywood, not really baltic birch, which is a grade higher.

The stuff I am using was made in China, but it is readily available. I don't have easy access to a nice woodworking store that has flexable hours like a home dept does.

 

[JCTewks]

The quality of the Chinese import plywood has GREATLY improved in the last 4-5 yrs. It used to be that most of it was made with low quality glues and questionable "hardwood" ply's. If you buy ply with a reputable companies name on it you are more than likely getting a good product as the reputable co's won't sell the crappy stuff anymore and have found factories in china that will do it "right". It's still not baltic....but it's getting closer to that quality

 

[chriscobb]

Any updates on the tank build

 

[AcroSteve]

Funny you should ask. Yes, I have been working on the steel framework and the integration of it for the last week or so. I should have some pics by the end of the week.

Nothing is welded/glued or glassed yet, but I am getting very close.

 

[chriscobb]

Cool looking forward to the updates

 

[AcroSteve]

Well, I did use my table saw as much as I could. Here is my auxiliary fence for cutting the groove for the angle in the long side of the bottom. The end was done with the previously mentioned hand saw.

Here is almost everything dry fit and ready to weld. I need one more piece of small angle - say about 3/4 or so for the left front corner. Pretty much only for support during construction, but it will be thin enough that I will probably leave it in after the glass is installed.
Currently, I am just using a piece of wood to support the upper pieces.

Closeup of the overflow. I used 1-1/2 on the back and will be cutting some of it out here in the overflow for some additional clearance. You might be able to make out my layout line.

Here are some closeups of the "joints". These will be welded and ground smooth. Originally, I bought some scrap 3/16x1-1/2 angle that prooved to be a little too rough. I purchased 20' of 1/8X2" angle for most of the front and perimeter. However, I needed more than 20' so I was able to use some of the better pieces of the 1-1/2. Should work out fine. Everything viewable from the front and side will be covered with wood anyway.

Keep in mind, this is angle and the other 2" leg is inserted into a groove I cut into the edge of the plywood.

Now, all I need is for my buddy "radone" to get that tank of argon so I can start welding. :lol:

You guys send him a message or two so he doesn't forget.

 

[radone]

Anticipation is killing me

 

[AcroSteve]

Oh, and for you welders, I have some joint prep yet to do. So don't pick on me yet. :lol:

 

[stugray]

Is radone planning on TIG or MIG weld?

If it was TIG, a "good" welder could tack the joints in place where you have it clamped & a wet rag would "put out the fire" before it caused any damage.

That way it would fit like a glove exactly where you need it.

Stu

 

[chriscobb]

Hey Acro....looks good....if I'm understanding correctly you cut like a dado into your bottom piece to slide the lip of the angle iron into? Looks very good!!!!!

 

[AcroSteve]

<a href=showthread.php?s=&postid=13330272#post13330272 target=_blank>Originally posted</a> by stugray
Is radone planning on TIG or MIG weld?

If it was TIG, a "good" welder could tack the joints in place where you have it clamped & a wet rag would "put out the fire" before it caused any damage.

That way it would fit like a glove exactly where you need it.

Stu

That's the plan - TIG, but I will be doing the welding. I might let him look over my shoulder. :lol:

And yes, all the angle either fits into a dado or rabbit where it meets the plywood.

 

[chriscobb]

Another dumb question Acro that's been puzzling me on my build as well......I'm planning to start my plywood build shortly and was going to integrate the angle myself, but how are you planning to attach or secure the angle to the plywood and then with putting wood over top the angle and securing that as well outer shell on the front to the wood behind it?

 

[ReefEnabler]

awesome work!!

As somebody with almost no experience welding/working with metal, I'm interested in any and all details/pictures you provide about the next part of the process.

this is going to be one tough tank, that's for sure.

 

[AcroSteve]

<a href=showthread.php?s=&postid=13331333#post13331333 target=_blank>Originally posted</a> by chriscobb
Another dumb question Acro that's been puzzling me on my build as well......I'm planning to start my plywood build shortly and was going to integrate the angle myself, but how are you planning to attach or secure the angle to the plywood and then with putting wood over top the angle and securing that as well outer shell on the front to the wood behind it?

Not dumb at all.

The angle shown will be "attached" to the plywood with West epoxy thickened with adhesive additives. Additionally, I think I am going to drill some 3/8 holes through the angle and plywood and insert wooded dowels for some definite positive attachment.

After this, I think am going to wrap the fiberglass cloth around from the inside to the outside of the tank.

The wood trim will be attached also with epoxy.

 

[radone]

Any updates?

 

[hotwired99]

I keep getting emails of updates on this thread but dont see any on the thread. Is it just me? What am I doing wrong. All my other subscription work fine.......

 

[AcroSteve]

I have been doing some welding, but I am having a terrible time keeping things square. Stainless draws much more than regular steel.

 

[Fiziksgeek]

I tried to make a post here yesterday, but got an error once I hit submit. The post never showed up, but now I get the email updates like I am subscribed to the thread now. RC glitch I guess....

Anyway, I was trying to post that I built a tank with similar construction methods. Mine is 55x40x28. I made a steel frame of 2x2x1/8wall angle. Welded it up, and fit the plywood to the inside. I drilled and counter sunk all edges for wood screws about every 3 inchs (took forever!). I thickened up some epoxy to the consistency of peanutbutter. I sanded the steel down to bare metal with my trusty angle grinder, put down a thick layer of the thickened epoxy, put in the plywood and pulled it tight with the screws (squeezes out excess epoxy). The epoxy acts as an adhesive and also fills and gaps between the steel and wood.

I did a single external overflow also (of a more basic design). Instead of running a piece of angle along the back top edge, I lowered it down about a foot, and turned it out so it acts as a support for the external overflow. Hope this makes sense. I will try to post a pic or two later.

<a href=showthread.php?s=&postid=13467191#post13467191 target=_blank>Originally posted</a> by hotwired99
I keep getting emails of updates on this thread but dont see any on the thread. Is it just me? What am I doing wrong. All my other subscription work fine.......

 

[chriscobb]

Still following as well

 

[AcroSteve]

Well, I have been having a terrible time welding this stainless steel. This is the 1st time I have used it for anything requiring tight tolerances. And boy, did I have some learning to do.

If you have welded before, you know that metal shrinks when you weld it. But stainless REALLY shrinks.

I feel that I have reached a milestone today, even though I am not yet finished welding.

After cutting apart several joints several times, I developed a procedure to get things spot on square. :thumbsup:


The front lower left joint was cut apart and re-welded at least 5 times.:hmm3:
When I say I cut the joints apart, I only cut the "flat" position of it. This allowed me to adjust the angle without completely re-ding the joint.

As I posted before, I had everything dry fit and clamped up on the plywood. I tack welded all the joints on the top perimeter and then filled in some of the welds before I removed the frame and finished welding it up. I had everything right on the money when I 1st started to weld and never re-checked it until I was almost done. I think I was about 3" out of sqaure by then. :eek1:

That's when I started cutting some of the joints apart and trying again. Anyway, what ended up working was takin the frame outside and welding one joint at a time, a little at a time and cooling it off with a garden hose between welds. Before this, I had just cooled the joint down with a wet rag until it stopped sizzling. But the metal was still hot to the touch. This did not work. It has to get back to room temp.

So, almost all the joints ended up just a little shy of 90deg. This is a good thing. I then beat the joints with a ball peen hammer to relive the stress. This also cased the angle to open up a little and I was able to get it right on 90deg after several good smacks.


Anyway, i have a good procedure now and will finish up the welding soon.







Here is a joint with some small tack welds.

Same joint after the 1st weld pass. Welding the whole joint in one pass makes a 90deg angle into about an 80deg joint. :rolleye1:

Here is the top perimeter frame. This will provide a significant portion of the structural integrity of the tank.
You can make out the area above the overflow where I cut away some of the angle iron for some additional clearance.

At this point, the euro brace is 1/16 out of square. Well within my target of 1/8" :lol: