A Different Beckett Housing Design

[weatherson]

I thought I would share a new Beckett injector housing I recently made for an upcoming dual injector skimmer I will be making. These injector housings are nothing new in overall design but rather just a different way of fabricating them. I'm posting this just to show that and not to try and say this is the end-all be-all way to do it. I decided to go with an all acrylic design that I machined on my drill press. I started with six 1" acrylic pieces ($3 each) that measured 2 3/4" square. I also purchased some 2 1/2" acrylic cylinder ($6/foot) and cut two sections at 3 1/4'.
Of the three 1" acrylic blocks per housing, I started with the top. On this piece I drilled a center hole and threaded it with a 1" pipe thread tap. This is to accept the PVC plumbing fitting for the intake side.

 

[weatherson]

Next, I machined grooves into the middle and bottom pieces where the acrylic cylinder is recessed into these blocks. This makes for a very strong joint compared to simply but joint and gluing them. Here I used a circle cutting bit (from Harbor Freight) and adjusted the outside diameter of the cut to 2 Ã"šÃ‚½Ã¢â"šÂ¬Ã‚. The cutter is slightly larger than the thickness of the cylinderââ"šÂ¬Ã¢"žÂ¢s acrylic but this could be improved by grinding it to the same. I didnââ"šÂ¬Ã¢"žÂ¢t feel this was needed since a full Ã"šÃ‚½Ã¢â"šÂ¬Ã‚ of the side and the end were plenty of surface area for a strong bond.

Next, I drilled the bottom pieceââ"šÂ¬Ã¢"žÂ¢s center out and tapped it as I did the top piece. Then I machined a rabbit recess the diameter just slightly larger than the Beckett bottom sleeve and machined a small groove there to hold a O ring in place. I also drilled the middle piece with a center hole just slightly larger than the diameter of the topââ"šÂ¬Ã¢"žÂ¢s threaded hole, big enough not to interfere with the Beckett injector. An O-ring is slid over the top of the Beckett injector and when assembled, rests snuggly against the bottom of the 1ââ"šÂ¬Ã‚ threaded plumbing coupler. The Beckett injectorââ"šÂ¬Ã¢"žÂ¢s top slides into this connector with a nice fit. The O-ring provides a water tight seal.

Next, I sandwiched the top and middle sections together and drilled the four holes that will accept the four bolts that hold them together. Then I drilled the topââ"šÂ¬Ã¢"žÂ¢s holes larger so the bolts freely pass through and tapped the middle pieceââ"šÂ¬Ã¢"žÂ¢s holes with Ã"šÃ‚¼ - 20 threads. The bolts slide down through the top piece and thread into the middle piece. I used stainless steel button-head-allen with flat washers. The 1ââ"šÂ¬Ã‚ thickness of the pieces requires no seal to be used but can have an O-ring between for added safety. This is one of the strength benefits to working with this thickness of acrylic.

 

[weatherson]

Here are a couple of shots showing all the pieces after machining, sanding and finish polishing. Note that this is prior to drilling the Ã"šÃ‚¼Ã¢â"šÂ¬Ã‚ pipe thread hole that accepts the air intake valve. I did this last as this hole passes through the middle piece side as well as the edge of the cylinder piece once itââ"šÂ¬Ã¢"žÂ¢s glued together.

And a shot with slightly different angles.

 

[weatherson]

Here's a shot of one of the injector housings after assembly and prior to drilling the air intake hole.

 

[weatherson]

And last of all, a shot of both units with their air intake valves installed. I'm waiting for a second injector to fill the one on the left. Also, I used a close threaded nipple at the bottom between the housing and union.

That's pretty much it. As soon as I get the skimmer completed and on the tank with these housings, I will post some more photos.

Joseph

 

[capncook]

thats one beefy housing! nice machine work...

 

[jcato]

overkill, but very nice work.
john

 

[weatherson]

capncook & jcato: Thanks. Overkill... perhaps. Fun with acrylic... definately!

Joseph

 

[Lunchbucket]

dude those ROCK!!!

start selling those back boys!! i would like a set please!!!!!!

Lunchbucket

 

[H20ENG]

Fun with the mill!

 

[weatherson]

Lunchbucket: Unfortunately, on a hourly labor rate, it would be cost prohibitive. A fun project though.

H20ENG: Exactly!

 

[Lunchbucket]

come on...just one

Lunchbucket

 

[marm64]

That is great.

How did you get the acrylic so clean looking after working on it? mine is always cloudy when I am done.

 

[Zephrant]

Wow- Very nicely done. And you know how to take pictures too!

I think you could get away with 3/4" or maybe even 1/2" thick acrylic for it, and save a little maybe.

Nice job on the valves- I hate to see people try to tap acrylic tube, and I like the way you avoided needing to do that.

Great job-


Zeph

 

[weatherson]

Lunchbucket: You're beginning to sound like someone with an awful lot of money to burn.

marm64: Lots of sanding and then flamed the areas the buffing wheel wouldn't reach. Did I mention lots of sanding? Thanks for the kind words.

Zephrant: You are probably right in that I could have saved a few bucks and went with thinner blocks but that would eliminate that cool look of the 1" stock. Thanks for the kind words. I take them as very high praise coming from yourself as I have admired your work for some time.

Joseph

 

[steve68]

wow that is awesome great job

 

[weatherson]

steve68: Thanks. I appreciate the comment.

Joseph

 

[Lunchbucket]

nope not a lot of money to burn just think that is one SWEET ARSE idea....guess they would be like 50buckes each the way you talk....OUCH! they look AMAZING though.

i bet if you used thinner acrylic and got it down there would be a little market for them...they look so puurrty

Lunchbucket

 

[marm64]

I just got some 3/4" cell cast that I might try this with. If I can get it to look half this good I think that I would put the skimmer out of the sump.

 

[williamrandel]

Very impressive. Judging from the side view, If you had used 3/4" or 1/2", your threads on both the beckett and the pvc fitting would have protruded through. ( That ought to justify "playing" with the thick stuff.