I've been drawing and modeling different lights for a while. I finally settled on a suspended lighting fixture for a couple of reasons. First, I dislike hoods on aquariums, I feel like they make the tank look too bulky. Second, this whole design is around a more modern looking set-up with just a touch of industrial/rustic, which matches the rest of our home. It's tough to get a 300g aquarium to blend in, right!?!?
After a few designs, we settled on this version, which will be suspended above the tank by thin wire. This 3D model is done in SketchUp, which I use quite a bit, as you've seen from the initial plans in the beginning of the thread.
I also end up with a pretty accurate cutlist, which makes life easier during the build.
Now, honestly, I still had no real idea on the types of wood and finish I was going to use. I thought a lot about using real reclaimed wood but opted not to for 2 reasons; 1: It can be a pain to get straight and flat boards from old wood. And 2: Old wood might have flaky lead based pain dropping into my reef. So I opted for a manufactured aged barn wood from home depot that was very reasonable. I also wanted a little contrast, so I opted to get cedar for the center where the kessils protrude.
I also did a slight design change on the ends. Originally The ends were wood but I wanted a more industrial look so I changed the design a bit to add steel ends that would be bolted onto the wood. I got the idea after coming across a metal finishing video where they polished the metal with a torch. It came out so amazing, I hat to try it out. (steel is to the right of the cedar in this pic)
First, you need a good clean tablesaw, so I cleaned mine up and waxed the top. Ain't she pretty! lol
I started with the middle section that would house the 4 Kessil 360WE lights and the ballasts for the T5's. After cutting the board to length, the exact location for each light was measured and marked. They are all evenly distributed to provide each 2ft section of the tank with light. A 6" hole saw makes for a perfect fit!
The sides use the grey barnwood. I cut
dadoes into these boards and then inserted the cedar board and glued it up. Here is the setup for the dado cuts. I needed a few guides to keep the twisted boards flat.
Because some of the boards had a twist in them, I glued it up in 2 stages. Lots of clamps were required!
The design is really simple actually, with the center "Kessil section" requiring the most work. The steel end plates hold it all together for the most part. I cut the steel plates to length and drilled 2 evenly spaced holes on each side. The top holes on these plates are also where I will attach the wires for hanging the fixture.
Once that was done, I dry fitted all the parts and then moved on to the fun part, the flame polish before final assembly and wiring...