onetrickpony
Premium Member
Most excellent, inspiring
Ken
Ken
A First Plywood Project...
- Thread starter Sean : EbN
- Start date
NY_Englishman
Premium Member
Sean,
Thanks for documenting this. It is a great thread and I think your DIY tank is one of the best I've seen - it's well thought out and well made, too. I intend to do something similar and am eagerly watching your tank's development.
Please keep the information coming. I'll chime in wherever I can but it looks like you've got most bases covered.
Cheers,
Englishman
Thanks for documenting this. It is a great thread and I think your DIY tank is one of the best I've seen - it's well thought out and well made, too. I intend to do something similar and am eagerly watching your tank's development.
Please keep the information coming. I'll chime in wherever I can but it looks like you've got most bases covered.
Cheers,
Englishman
Sean : EbN
New member
A blue day...
A blue day...
Hello all...
First of all I apologize for not having any photos of the tank tonight. I moved it out to my loading door in my shop to help dissipate some of the fumes from the AquaticEco paint. It is still gummy enough that it will be damaged if I try to move it so photos tomorrow!!
Last night I sanded down the repairs to the damaged area (from where it toppled off the sawhorses and crashed to the floor) as well as laid a 2nd coat of West System epoxy to the top and front, a 3rd coat to the inside of the overflow trough, the interior seams and the interior face frame (that the glass will seat against)
This morning I hit everything with a combo of 100 and 220 grit sandpaper with the power orbital sanders and got to painting! I think I will be wearing long sleeves for a few days... my arms are blue! While painting the inside of that trough my arms got covered with epoxy pretty good. I got the epoxy to come off pretty easily with Acetone but the coloring agent sort of soaked in. Oh well... I'll get over it! I used almost the whole gallon to put 2 coats on every surface. I had about an inch left in the bottom that I just tossed. So basically all surfaces that will have direct water contact on the interior of the tank have 3 coats of West Systems epoxy and 2 coats of AquaticEco's dark blue 2-part epoxy paint. Also the first West coat was applied to the interior of the display tank along with #6 woven fiberglass on all flat and corner surfaces. This coupled with the West filleting that I applied in my first steps have made and EXTREMELY strong structure. On the exterior I have 2 coats of West System epoxy and 2 coats of AquaticEco's dark blue 2-part epoxy paint. Think it'll hold water?!?
Tip for the AquaticEco stuff... put it on really light! The back panel of the display has several sags where I applied it a bit too thick. I tried to keep it from sagging as much as possible but it didn't quite come out right. I think I am going to try to wet sand them out a bit after the paint has hardened. Also... I read somewhere that you should put your brushes in the freezer between coats to keep them from hardening... good tip!! Also... another tip... for painting in tight spots where it is hard to move a brush back and forth (such as my 96"x12"x8" overflow trough) I took an adhesive roller, like the ones you can buy at Home Depot with the little stubbly bristles, and cut them lengthwise to make 2 semi-cylinders and then cut those in half leaving me with 4 pieces similar in size to if you cut a toilet paper roll in half lengthwise . I used these 4 pieces like a paint brush, wetting the arc with paint and just rubbing it on. It worked great and left a nice smooth finish. West Systems recommends that for use as a final finishing tool for top-coating. I hope these tips help someone!
Finally... the glass! I called and ordered it today. Not so sure if I got a good deal or not but at least I found a nice, honest person to get a price from! It is a 92.5"x26.5" piece of 1/2" tempered STARFIRE glass
I called EVERYEHERE and got to speak to a bunch of non-knowlegeable, rude individuals. The price was $480+tax but I feel good that I got the STARFIRE name. The problem is it will be 3 weeks before I receive it 
Due to Hurricane Katrina causing so much damage to my area, commercial glass tempering companies are WAY backed up. Oh well... I guess I have more time to think about plumbing and filtration. Also, I think I want to epoxy in a section of steel angle on the front-top-center and rear=top-center to pass a threaded rod through just in case I have to tension the front top to aleviate bowing. Just a precaution that is easier to apply in the construction stage than after filling.
Oh well... this has been a bit lengthy with no nice photos to make it worth your while reading so check back tomorrow!!
BTW... great to see you all tagging along!
HAVE FUN!
A blue day...
Hello all...
First of all I apologize for not having any photos of the tank tonight. I moved it out to my loading door in my shop to help dissipate some of the fumes from the AquaticEco paint. It is still gummy enough that it will be damaged if I try to move it so photos tomorrow!!
Last night I sanded down the repairs to the damaged area (from where it toppled off the sawhorses and crashed to the floor) as well as laid a 2nd coat of West System epoxy to the top and front, a 3rd coat to the inside of the overflow trough, the interior seams and the interior face frame (that the glass will seat against)
This morning I hit everything with a combo of 100 and 220 grit sandpaper with the power orbital sanders and got to painting! I think I will be wearing long sleeves for a few days... my arms are blue! While painting the inside of that trough my arms got covered with epoxy pretty good. I got the epoxy to come off pretty easily with Acetone but the coloring agent sort of soaked in. Oh well... I'll get over it! I used almost the whole gallon to put 2 coats on every surface. I had about an inch left in the bottom that I just tossed. So basically all surfaces that will have direct water contact on the interior of the tank have 3 coats of West Systems epoxy and 2 coats of AquaticEco's dark blue 2-part epoxy paint. Also the first West coat was applied to the interior of the display tank along with #6 woven fiberglass on all flat and corner surfaces. This coupled with the West filleting that I applied in my first steps have made and EXTREMELY strong structure. On the exterior I have 2 coats of West System epoxy and 2 coats of AquaticEco's dark blue 2-part epoxy paint. Think it'll hold water?!?
Tip for the AquaticEco stuff... put it on really light! The back panel of the display has several sags where I applied it a bit too thick. I tried to keep it from sagging as much as possible but it didn't quite come out right. I think I am going to try to wet sand them out a bit after the paint has hardened. Also... I read somewhere that you should put your brushes in the freezer between coats to keep them from hardening... good tip!! Also... another tip... for painting in tight spots where it is hard to move a brush back and forth (such as my 96"x12"x8" overflow trough) I took an adhesive roller, like the ones you can buy at Home Depot with the little stubbly bristles, and cut them lengthwise to make 2 semi-cylinders and then cut those in half leaving me with 4 pieces similar in size to if you cut a toilet paper roll in half lengthwise . I used these 4 pieces like a paint brush, wetting the arc with paint and just rubbing it on. It worked great and left a nice smooth finish. West Systems recommends that for use as a final finishing tool for top-coating. I hope these tips help someone!
Finally... the glass! I called and ordered it today. Not so sure if I got a good deal or not but at least I found a nice, honest person to get a price from! It is a 92.5"x26.5" piece of 1/2" tempered STARFIRE glass
I called EVERYEHERE and got to speak to a bunch of non-knowlegeable, rude individuals. The price was $480+tax but I feel good that I got the STARFIRE name. The problem is it will be 3 weeks before I receive it Due to Hurricane Katrina causing so much damage to my area, commercial glass tempering companies are WAY backed up. Oh well... I guess I have more time to think about plumbing and filtration. Also, I think I want to epoxy in a section of steel angle on the front-top-center and rear=top-center to pass a threaded rod through just in case I have to tension the front top to aleviate bowing. Just a precaution that is easier to apply in the construction stage than after filling.Oh well... this has been a bit lengthy with no nice photos to make it worth your while reading so check back tomorrow!!
BTW... great to see you all tagging along!
HAVE FUN!
onetrickpony
Premium Member
Sounds like you are making great progress
The delay in getting the glass will give you time to work on the stand
As for the price for the glass, I think you got a great deal
All the people I get to talk to, quote me twice price you got
Have you thought of using threaded rod instead of the angle iron for the top brace?
Less shadows from the lights
Keep the pictures coming?
Hopefully I can start mine next year
Ken
The delay in getting the glass will give you time to work on the stand
As for the price for the glass, I think you got a great deal
All the people I get to talk to, quote me twice price you got
Have you thought of using threaded rod instead of the angle iron for the top brace?
Less shadows from the lights
Keep the pictures coming?
Hopefully I can start mine next year
Ken
Sean : EbN
New member
Hello Ken,
Thanks for commenting on the glass pricing. I thought the guy was really nice (maybe too nice) and might have been putting the screws to me. I guess not! I'm really looking forward to getting that glass as I've never personally seen a filled aquarium with Starfire glass in person.
Ahhh yes... the stand... Well this tank will be pushed right up against a wall and the 9x6' room directly behind it will be used as the "tank room" complete with a sink and all. Before I build the stand I have to get this tank room in order because I have to set-up my sump and "frag tank" to hold all of the rock and softies in my current 90 gallon that sits against the wall that the new 340g is going to be on... what fun! I already have the frag tank, it is a 65 (36x18x24) that is already drilled w/overflow and the sump which is this weird custom tank I used to have in my shop that is 42x15x24, it still has to be drilled. After all of that is set up I have to start work on the stand. Also have to get my electrician in there to hook up a little load center for the tank to feed from.
As for the top brace... I am going to use the threaded rod. I am using the angles steel parallel to the front and back, mounted on the top of the tank to pass the rod through and then put nuts and fender washers on the rod. I can then remove the rod if need be.
I promise I will have some photos later today!
Thanks...
Thanks for commenting on the glass pricing. I thought the guy was really nice (maybe too nice) and might have been putting the screws to me. I guess not! I'm really looking forward to getting that glass as I've never personally seen a filled aquarium with Starfire glass in person.
Ahhh yes... the stand... Well this tank will be pushed right up against a wall and the 9x6' room directly behind it will be used as the "tank room" complete with a sink and all. Before I build the stand I have to get this tank room in order because I have to set-up my sump and "frag tank" to hold all of the rock and softies in my current 90 gallon that sits against the wall that the new 340g is going to be on... what fun! I already have the frag tank, it is a 65 (36x18x24) that is already drilled w/overflow and the sump which is this weird custom tank I used to have in my shop that is 42x15x24, it still has to be drilled. After all of that is set up I have to start work on the stand. Also have to get my electrician in there to hook up a little load center for the tank to feed from.
As for the top brace... I am going to use the threaded rod. I am using the angles steel parallel to the front and back, mounted on the top of the tank to pass the rod through and then put nuts and fender washers on the rod. I can then remove the rod if need be.
I promise I will have some photos later today!
Thanks...
Carl_in_Florida
Active member
Where are the photos?
Carl
Carl
Sean : EbN
New member
F I N A L L Y!!
F I N A L L Y!!
Hello all...
After a really long day I finally got to this, sorry folks. Here they are...
Please let me know if you have any questions about it... I'm beat!
Thanks!
F I N A L L Y!!
Hello all...
After a really long day I finally got to this, sorry folks. Here they are...
Please let me know if you have any questions about it... I'm beat!
Thanks!
All i can say at this point is WOW!!:eek2: Nice job all around! Do you think this tank will be heavier than if it was all glass?I would like to do one in the 200 gal. range and weight is an issue where i would need put it.I am interested in the cost for the epoxy as i know its pretty expensive.Keep the updates going as i am looking foward to seeing that bad boy filled. Thx for all the info so far!
NY_Englishman
Premium Member
Thanks for the pics, Sean. I think it's come out really nice - looks excellent and built like the proverbial out house.
May I ask a few questions?
How many helpers will you have to put the glass in place? Will you make any temporary jig to support the glass above the frame before lowering it into position?
What special precautions against the "window" frame not being sufficiently flat have you taken? I, like you, have trawled the web for every DIY tank documented on the web and I noticed one guy had this issue with the frame i.e. when he'd laid the bed/sausage of silicon, he lowered the glass to find the receiving frame wasn't sufficiently flat (mania quickly ensued). My guess is because of your frame thinkness/construction method you'll be just fine.
Have you kept a record of the hours you've put into the construction of this? If not, would you estimate this figure for us following this thread? People have said to me that my 10ft+ tank will take months but I'm planning on just 100 concentrated hours.
Your tips along the way will be of great help, at least to me, by the way!
May I ask a few questions?
How many helpers will you have to put the glass in place? Will you make any temporary jig to support the glass above the frame before lowering it into position?
What special precautions against the "window" frame not being sufficiently flat have you taken? I, like you, have trawled the web for every DIY tank documented on the web and I noticed one guy had this issue with the frame i.e. when he'd laid the bed/sausage of silicon, he lowered the glass to find the receiving frame wasn't sufficiently flat (mania quickly ensued). My guess is because of your frame thinkness/construction method you'll be just fine.
Have you kept a record of the hours you've put into the construction of this? If not, would you estimate this figure for us following this thread? People have said to me that my 10ft+ tank will take months but I'm planning on just 100 concentrated hours.
Your tips along the way will be of great help, at least to me, by the way!
Sean : EbN
New member
Hello everyone,
tabndust : The next step (while I'm waiting for my glass) is to begin work on the tank room. Right now it is a "kitchenette" for employees here at the shop. I have an exact clone of it next door in the other unit that I rent for my business, that will be the new kitchen and the old kitchen will be the tank room with all the guts for the main display. It needs paint on the walls and floor as well as an electrical load center (probably a 60 amp extension) for everything to plug into. That is my next BIG step. Also, thanks for the compliment.
joeski : Thanks I don't know exactly how much a 300-350 gallon tank weighs. I can tell you that this tank weighs somewhere in the 175 lbs neighborhood. as for the glass? I don't know yet. The West Systems epoxy was expensive, about $100.00 "per gallon" which was for the gallon of resin and the container of fast hardener. I'd say as of right now, the tank has cost about $1000.00 including the Starfire glass front. If you have read this entire thread you will see a post, on page 1 I believe, that has some website links to some other high quality Epoxy dealers with great prices compared to West Marine. My West dealer was very friendly and somewhat helpful as well as convenient.
NY_Englishman : Thank you too for the compliments. The glass will probably be placed by myself and one other. I may arrange for more people on hand when I get the glass in. As for a jig I was thinking about using a floor jack (automobile style) with some sort of support structure to lower it in the tank as well as to seat it against the front lip. As for the front frame, I used the birch plywood which was almost perfectly flat. I sanded my butt off to be sure that it was really slick and flat. If the jack method works, I will dry fit the glass to the face frame before applying the silicone. I don't recall really having to tweak the front to get it in straight. I used a great Millwaukee circular saw with a Freud Diablo blade and a brand new straight edge to cut the pieces. There were very little assembly problems at that stage. I'm confident!
Hours... ahhh the magical question. Well I tend to work like this in 3 hrs. bursts and I didn't really keep track. I'm just guessing here but I say no more than 30 hrs and no less than 20 hrs. I'll keep you posted!
Thanks guys... gotta run but I'll bring more news and answers later.
tabndust : The next step (while I'm waiting for my glass) is to begin work on the tank room. Right now it is a "kitchenette" for employees here at the shop. I have an exact clone of it next door in the other unit that I rent for my business, that will be the new kitchen and the old kitchen will be the tank room with all the guts for the main display. It needs paint on the walls and floor as well as an electrical load center (probably a 60 amp extension) for everything to plug into. That is my next BIG step. Also, thanks for the compliment.
joeski : Thanks
I don't know exactly how much a 300-350 gallon tank weighs. I can tell you that this tank weighs somewhere in the 175 lbs neighborhood. as for the glass? I don't know yet. The West Systems epoxy was expensive, about $100.00 "per gallon" which was for the gallon of resin and the container of fast hardener. I'd say as of right now, the tank has cost about $1000.00 including the Starfire glass front. If you have read this entire thread you will see a post, on page 1 I believe, that has some website links to some other high quality Epoxy dealers with great prices compared to West Marine. My West dealer was very friendly and somewhat helpful as well as convenient.NY_Englishman : Thank you too for the compliments. The glass will probably be placed by myself and one other. I may arrange for more people on hand when I get the glass in. As for a jig I was thinking about using a floor jack (automobile style) with some sort of support structure to lower it in the tank as well as to seat it against the front lip. As for the front frame, I used the birch plywood which was almost perfectly flat. I sanded my butt off to be sure that it was really slick and flat. If the jack method works, I will dry fit the glass to the face frame before applying the silicone. I don't recall really having to tweak the front to get it in straight. I used a great Millwaukee circular saw with a Freud Diablo blade and a brand new straight edge to cut the pieces. There were very little assembly problems at that stage. I'm confident!
Hours... ahhh the magical question. Well I tend to work like this in 3 hrs. bursts and I didn't really keep track. I'm just guessing here but I say no more than 30 hrs and no less than 20 hrs. I'll keep you posted!
Thanks guys... gotta run but I'll bring more news and answers later.
NY_Englishman
Premium Member
Thanks Sean for the specifics ref blade and materials - it sounds like you have that base covered! The floorjacks might help or then, again, you may not need them. Can't wait to see the tank with the glass in it - please keep the photos coming.
Awesome tank! I have used West System for boat repairs. You have sure done an excellent job of construction. My question goes way back to the begining. Where/how did you get the orginal plan/design for cutting the wood and design of the overflow etc? I would love to build one (on a smaller scale)
Keep those pictures coming!
:thumbsup:
Keep those pictures coming!
:thumbsup:
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