500 Gallon DIY Build

juststartingout

New member
Hi fellow reefers, things are starting to slow up a bit, so I thought I would throw up my build thread.

A little history:
Started out with a 160 gallon acrylic tank built in Minnesota. The top seam failed on it, so when I called the builder he honored the "lifetime" warranty. I figured this was a good time to upsize, so I paid for the difference in tanks and built out a 450 gallon acrylic tank.

Tank was going great unit I reversed the input/output kalk mixer lines. Came down to the basement & seen the water was extremely cloudy and ph was in the 9.5 - 10.5 range. Using vinegar I brought it down and did several large water changes in a row (as quickly as I could prep 100 gallons) . All fish & two anenome's survived, but lost all of my coral. Most died right away, some had decined and had taken a couple weeks, I couldn't bring them back. Went with basically a FOWLR for a bit.

Back in November 2011, I noticed several white (cloudy) area's in the bottom/side seam in the tank. I tried several times to contact the tank builder in Minnesota and tried sending him pictures of the tanks seam, but he said he never recieved my emails. When I was able to talk to him on the phone, he said to send him pictures via email. Finally I think he may have recognized my phone # because my calls always went to voicemail, and he never returned any of my calls. I knew I was not going to get anywhere with him and I had a faulty seam in a 450 gallon box of water. :furious:

I asked the wife, "Do you want to stay with the hobby or get out"? We need a tank and its going to run several thousand $$. Being the animal lover she is, her reply was "since you have all of this money tied up already, and some beautiful fish, let's stay in". :celeb3:

Being a bit on the handy side, and after checking some pricing and dealing with the challenge of getting the tank in the basement. (The 450came though a window that I had to remove.) I figured the best solution would be to build it in place. The old tank was a 36" wide and I didn't want to go through that hassle again! Plus, I snuck in an extra 12" on the width, shhhh. :dance:

I decided that I was going to build my own. Afterall, my acrylic tank appearantly had no warranty, and some of the glass tanks I seen didn't have much either, plus you had to use their stand. Now thats fine for alot of people and there's nothing wrong with that, but I love a good challenge.

So on the the present:
The tanks dimensions are 96" x 48" by 30" the overflow height is 26.5". The overflow is at the right end (coast to coast) it's external with 4) 1.5" drains. The glass is 3/4" thick, actually 19mm as I think it is metric. I used Momentive RTV clear silicone adhesive. Wakesurfdan was a big inspiration to building this myself. After studying his technique and following his tips, I started the build.

I know the drill, pictures or it didn't happen.









 
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Some pictures of the stand...


The top frame in the background gets set on the bottom frame. All joists & studs match up, due to the math, they are set to 15"oc. It is made from 2"x8" pressure treated wood.


 
Thanks,
Coming from a 36" wide tank I had to add additional lighting. I was running 4 Luminarc's down the center of the old tank. I have added 4 Tek Elite fixtures to cover the additional area. They are the 4 bulb units and flank each side of the MH's.
 
Looking good, I just looked at your pictures before I read your thread and thought wow that jig looks familiar. Then I read it and found out why. Need any help along the way let me know. My tank has been up and running now for 8 months and is thriving.
 
All of the glass came from glasscages. The crew over there was very easy to work with and the cuts were right on the money.


Installing the top bracing...


This is the right side of the tank, the external overflow box will be mounted here, once I clean up a bit of silicone.


The overflow box...


Installing the overflow...


Finishing off the overflow...
 
Looking good, I just looked at your pictures before I read your thread and thought wow that jig looks familiar. Then I read it and found out why. Need any help along the way let me know. My tank has been up and running now for 8 months and is thriving.

Dan, thanks for lighting the way. You answered the questions that I had in your build thread and the video's you posted were a big help. I know my inexperience had shown when laying the corner bead of silicone, not nearly as good as I'd like it to be, but it's behind a wall. The joints came out good though. It's already leak tested and filling with ro water as we type. :dance:
 
Temporary tank...




Hope to have the new tank ready to change over next week. Based on the water level & the rate of fill, it may be full by about Monday or Tuesday of next week. I'll get up early Saturday morning and have a few cups of ambition and swap it over.

I just recieved 150 additional pounds of rock. I ordered the BRS Pukani "dead rock". The rock looks fantastic, but I'm fully prepared to let it cook for a a month or two before putting it in my tank.
 
8 months later<a href="http://s1129.photobucket.com/albums/m512/Wakesurfdan/?action=view&current=79358ce4.mp4" target="_blank"><img src="http://i1129.photobucket.com/albums/m512/Wakesurfdan/79358ce4.mp4" border="0" alt="Photobucket Pictures, Images and Photos" /></a>
 
can u pm me cost of build or glass, was just wondering if it was cost effictive to do yourself or have it dont, im diy to, so just wondering
 
can u pm me cost of build or glass, was just wondering if it was cost effictive to do yourself or have it dont, im diy to, so just wondering

Zoonutt,
You have a pm. For me, there were a couple of reasons that I did it myself. The tank at this dimension had to be built in place,with the layout of my home. I like tackling projects like this and saving a bit of money is always a good thing.

Thanks for stoping by... :wave:
 
8 months later<a href="http://s1129.photobucket.com/albums/m512/Wakesurfdan/?action=view&current=79358ce4.mp4" target="_blank"><img src="http://i1129.photobucket.com/albums/m512/Wakesurfdan/79358ce4.mp4" border="0" alt="Photobucket Pictures, Images and Photos" /></a>

Looking great Dan! :beer:

thanks for sharing.
 
We started to fill the tank last Tuesday...


Here is where it's at now, still got a couple days to go. Once the tank is full the sump will need to fill up.


When I had taken my MRC MR-7R off line in favor of the SRO XP5000E, this gave me a spare Sequence 4300 pump. I decided to add it as another return pump from sump to tank. I had to increase my bubble trap a bit to accomidate the extra flow.
Before...


After...


Two pumps...


One pump pushes water through a 114wt UV sterilizer, both flow into the tank via 1 1/2" Sea Swirls. They create a good amount of flow. I had to dial the pumps back a bit while water testing a couple of weeks ago as the water was just rolling over the tank overflow.

I have a couple of Tunze 6255's on pre-order,I hope their worth the wait.
 
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