Acrylic fabrication questions? I can help!

I am putting an acrylic baffle in my acrylic sump to make two chambers. I ordered a tube of WeldOn 16 and bought a piece of .222" acrylic from HD.

Do I cut the piece of acrylic as close as possible to the size of the interior dimension of the tank so it fits tightly or should I leave it slightly loose? I plan to use a table saw or a track saw.

Do I clean the acrylic with isopropyl alcohol prior to gluing?

When gluing, do I put the WeldOn 16 on each end and bottom edge of the acrylic baffle and then run a bead around both sides?

Thanks.
 
Putting a baffle in an existing sump is pretty tricky to get it perfect. If there is a level difference on each side, then it will need to be sealed around the edges. If there is no level difference, then sealing the edges is less important.

In general, you should cut the piece so it is as snug as possible, not loose. You need the acrylic joints to be tight for the bond to actually form. WO16 is not a very good choice for this, because while it is a gel-like product, it is not a gap filler - it will dry to the same profile as WO4. But you can build up layers of it, which will take time, and may still not work well.

What I would recommend is cutting the baffle so that it fits in the position you wish as tightly as possible. Then, use WO4 and the pins method to get the bottom edge welded on, let sit for 20 minutes, then turn the tank on one side and pin the joint as best as you can and weld that one, sit 20, then flip and pin/weld the third side. You could do this using capillary action, but capillary joints don't bite into each side of the joint well, and when you put water in the tank and the panels bow outward, those joints will eventually pop. So this rather poor application of the pins method is much better than capillary any day.

The result will be joints that are relatively strong (as strong as you need them to be) but very likely will not be water-tight. it is very hard to get water tight joints when putting a baffle in an existing tank/sump. So, now you are left with a couple options.

The easiest is to run a very small bead of silicone along each side of the joint. It doesn't have to be much - you are not attaching one panel to the other, you are just filling in the corner to seal it, so literally a bead the thickness of a toothpick is adequate, plus a thinner bead will cure faster (some would still say to wait a few weeks, but meh...)

Another option is to bond in gussets to seal up the joint. Cut a few strips of scrap acrylic that you have left over into strips that you can weld in to the corners on one side of the baffle, or both if you feel like it. Gussets need only be 1/4" on a side for this type of job, but bigger if you want. Use the WO16 for this, run a bead in the corner then place the gusset in there, press and hold. Also hold your nose. WO16 is stinky.

You might also just use the WO16 without gussests, and just build up layers.

Alternatively, if you can't get WO4, you could just bond the whole thing in place with WO16, but you will only be able to really fill in the bottom joint before you push it down, then the side joints you would probably have to gusset on both sides. You might be able to get some WO16 into a pinned joint, but definitely not all of it - it does not wick in, at all. If you only have WO16, gusset both sides of all joints and call it good. Your gussets should probably be bigger for this, because the gusset is actually holding the walls from bowing, so you have outward pressure on the joints, which are already somewhat weak from WO16 (which is really junk).

Clean all the surfaces with alcohol, rubbing alcohol is probably better than nothing, denatured alcohol is better.

Rough cut with a table saw, then scrape with a razor blade to get a nice smooth edge. Getting the piece square so that all 2 sides make full contact is going to be the hardest part.

Also Home Depot stuff is generally your cheap import extruded stuff, so err on the side of caution (i.e. take extra steps to make sure the bonds hold). Make sure it is actually acrylic and not polycarbonate, which won't work.
 
Floyd,

Thank you for the thoughtful and comprehensive response. Not being able to find the WeldOn locally, I just ordered the #16 thinking it was pretty much equivalent to a thicker #4.

Based on what you say, it sounds like I might be best off gluing in a channel for the baffle and sealing its edges with the WeldOn. I could do one side of the channel, bond the baffle to that side and to the sump, and then bond the other side of the channel to the sump and the baffle.

I hope to have different water levels on each side of the baffle, so I can seal with silicone if there are leaks.

Regards,

Frank
 
Actually that brings to mind another option. Find a source of some square acrylic rod, or cut a few strips of your .222 material and laminate them together, then trim off one edge to make a square corner. Now bond that to the sides and bottom. That will create a bonding surface for the face of the baffle. Now bond the baffle to your rod or DIY rod.

I can sketch this for you if you want.

But the rod or rod substitute on the low-water side of the baffle. This way the pressure from the higher water side will push the baffle into the rod rather than trying to push the baffle off of it.
 
Sizing Questions

Sizing Questions

I plan on making a tank that is 270 gallons (72"L by 36"W by 24"H). I am planning using 3/4 inch for the front and back panels. Would I be able to use 1/2 inch on the sides? Also could I use something thinner for the bottom such as 1/4 since the bottom of the acrylic needs to be supported by something anyways? Just trying to cut a few costs if possible.
 
The acrylic material is not the area to skimp. Really, it's insurance. The thicker material, the better. What goes inside it is going to be way more valuable - your money, your time, your effort, all for naught if you build the tank wrong.

That being said, the bottom panel could probably be 1/2", minimum. Front/back/side panels could all be 1/2" actually at 24" tall, so going to 3/4" would really make it strong on front/back and sides could probably be 1/2".

Top euro is important too - you want that to be 3/4" if you can, and 3" perimeter euro with 6" cross brace every 24" (so 2 of them, at 24" and 48") and 3" radius cuts on all the corners of the holes. If you go 1/2" on the top, make the perimeter a little beefier.

Adam or James might chime in and verify all this for me though. That's just what I've learned from talking to them - I don't do big tanks yet, I just soak up and repeat info the best I can on that size build!
 
Thank you for your input. So let me just make sure I'm getting this right. I could get away with 1/2 on everything, but for reassurance, 3/4 on front/back and top euro with bracing would be best?
 
Yeah the only thing I would get input on is the thickness of the top euro. because of the width of the tank, you will need a full sheet each for the top and bottom.

Also the top euro I refer to is one piece with access holes cut into it, not a euro with bracing (a eurobrace by definition has bracing). It begs the question - is this your first tank build? Or are you specifying this for someone else to build? Just curious...
 
I am going to build it myself, but that is several years (yes years) away. I am doing as much research and planning as possible. I am getting as much input as possible. After that, I am going to get some practice on a small tank and sump before jumping in to something this large. Don't want to waste all that money on a failed attempt.
 
Hello. Thanks to everyone contributing to this awesome thread!

I'm building a rimless tank with a 24"x16" footprint, that will be 12" high.

The the thickness calculators all say I should go with a 3/8" thick, but I would like to use a 1/4" sheet- and from what I have read it's doable without a brace, but does anyone know if there will be noticeable bowing?

Also, has anyone ever made a bracing with the access hole so big that they are basically flush with the inside of the tank? Would this provide any support with a tank my size, or is this worthless? I guess this would only provide a little corner support but no bowing-prevention.

I want to use the minimum amount of plastic possible- I like ADA tanks but I want to use my dimensions and I want to make a custom overflow. I have no problem using 3/8", but I'd like to go thinner if possible.
 
I remember seeing a chart somewhere that suggested the thickness of acrylic depending on the size of the tank being built.

I need to build a customer 10 gallon tank.
6.5 wide, 15 long and 24 tall.
What thickness acrylic do I need to use?

Would it be the same if I went 36 tall for a 15 gallon tank?

This is going to be for ATO storage.
 
Hello. Thanks to everyone contributing to this awesome thread!

I'm building a rimless tank with a 24"x16" footprint, that will be 12" high.

The the thickness calculators all say I should go with a 3/8" thick, but I would like to use a 1/4" sheet- and from what I have read it's doable without a brace, but does anyone know if there will be noticeable bowing?

Also, has anyone ever made a bracing with the access hole so big that they are basically flush with the inside of the tank? Would this provide any support with a tank my size, or is this worthless? I guess this would only provide a little corner support but no bowing-prevention.

I want to use the minimum amount of plastic possible- I like ADA tanks but I want to use my dimensions and I want to make a custom overflow. I have no problem using 3/8", but I'd like to go thinner if possible.

IMO, If you are going to build a rimless tank with those dimensions, and you dont want it to bow. Use 1/2'' material.
If you use 3/8'' material , you will need to add a eurobrace.
If you want that size acrylic tank, Dont use 1/4''.
 
Man, I really didn't want to go that thick- for aesthetic and cost reasons. But I guess that's the trade off when using acrylic. I'd go glass, but I want a custom overflow.

My router is a craftsman 1.5 hp. Is this going to be powerful enough to properly cut a 3/8 sheet? How about a 1/2 sheet?
 
tizzite where is the thickness calculator? I can't remember where I saw it.
Also where are you getting your acrylic from?
 
Bending 1" acrylic for seamless 45 degree angle tank build

Bending 1" acrylic for seamless 45 degree angle tank build

Is it possible to router the thickness down on 1 inch . Sheet where seam is to make a seamless bend? Building huge tank with drops and angles need advice would love to be able to do this myself
 
Chaca, not sure I understand what you're asking. But just from your question, that sounds like a pretty complicated build - way past the hobbyist level.
 
Lexan is polycarbonate, don't use it for aquariums. Also that is way too thin for anything - 1/4" minimum. 3/8" if you can get it.
 
Does polycarbonate leach something into the water? I can find acrylic locally as well, but only .220. That's close to 1/4". Close enough?
 
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