Brian's 520 gal. Plywood Build + Fish Room
- Thread starter Brian Crook
- Start date
Brian Crook
New member
Thanks! I'll be sure to keep taking photos of the various steps. Regarding the outside of the tank, I will be treating it just like the inside (pouring where able, and brushing where not able). I've decided to basically cover the entire thing in epoxy.. haha
This is not necessary and is mostly a result of having purchased so much epoxy. But the fish room could be exposed to high humidity so it will be nice reassurance that there is absolutely no wood exposed in the final product. I cannot believe how hard and "plastic-like" this stuff becomes after it has finished curing - it is really impressive. For anyone else out there that is considering a plywood aquarium, go with a solid two-part epoxy like the one from US Composites - you will not be disappointed!
Looking good Brian. Yes, people always have concerns when someone else is doing it, until they do the same and realize how strong the tank actually is with all those layers, cross braces and glass in it. You will plenty fine with strength, no doubts about that. And I've built 2 800g tanks like this
Brian Crook
New member
Yeah for sure. I really wasn't expecting it to be so strong! I just finished pouring my last 'edge' tonight. This weekend I'll be focusing my attention on the final bottom and back pours, overflows, and finishing up on the top and front.
muttley000
MTS Sufferer!
This looks great! I used CyclistMT's advice on a sump a couple years back that is 279 gallons one everything is working perfectly! I have to do my first of 2 large builds next year to experience the glass part of the project, but I have found the pour method with2 part to work flawlessly. I'm really liking the external overflows on your tank too. A couple questions, because I will have to do the same on the ends how many coats would you say you brushed on the ends and where did you get the tools for rolling and getting the glass into the corners?
Brian Crook
New member
For the sides, I brushed on and wetted out the fiberglass as the first layer. Next I brushed on a black pigmented layer. After that one cured I sanded it and brushed on another. And then another after that. I plan on doing some light sanding and brushing on one more final coat (today in fact). So that'll be 5 layers.
It's possible to brush it on "vertical" if you allow the epoxy some time to kick / begin curing. As it starts to get thicker it is less likely to run down from where you brush it as a result of its own weight. I found this technique to be very helpful when doing the sides.
All of the tools and materials were purchased from US Composites. Great experience purchasing everything from them; highly recommended.
I still need to purchase the silicone. I'll be going with the RTV 103 black silicone. I'm still deciding how to go about setting the glass - either with the tank right-side-up and using some wood to "push" the glass into place and hold it, or with the front side down and setting the glass in place and putting some weight on top of it. I have decided not to create a 'ledge' of sorts for the glass to rest on, and will instead rely on the 1-3/4" wide silicone bead.
Have you noticed any degradation of the epoxy over the past couple years of use? Nothing I have seen so far indicates this but it's always great to hear first-hand experiences.
Brian Crook
New member
Nope, I've been holding out on photos until this thing is done! I'm close to having the epoxy done, at which point I'll post a bunch more photos to show the edges... But basically I rotated the tank 45 degrees in every which direction and poured in my epoxy fillets. When it cures it creates a nice smooth transition from wall to wall, to help distribute the load and provide even more strength.
I can't state this enough: this epoxy is incredible stuff!
Brian, my suggestion is to lay the tank on its front and place the glass down on the silicone. WORK FAST!!!!!! Silicone dries so very quick, u will have maybe 5 mins total to do it so angle the glass first, then run your silicone, then let the glass down. You will not have time to apply, the grab the glass then set it where you want, so make sure it's in the tank first
Also one the glass is in place, I suggest running a thick bead of silicone around the perimeter of the glass edge too. This is just precautionary in case the wood isn't comple flat.
Also one the glass is in place, I suggest running a thick bead of silicone around the perimeter of the glass edge too. This is just precautionary in case the wood isn't comple flat.
muttley000
MTS Sufferer!
Brian I have noticed absolutely no problems with the epoxy degrading. I am planning my next project as a display using the same epoxy again, except a different color. I did white on the sump and am glad I did. I am really liking the black you used!
Brian Crook
New member
The epoxy is (mostly) done! I sanded down the front, top, overflows, inside back, sides, and inside bottom, and over the past few days worked on applying the final coats of epoxy. The edges turned out great, however it was virtually impossible to prevent a bit over of dripping from occurring while I was applying the final coats to the sides, so there's some visual imperfection on the edges below the sides. I had to remind myself that it doesn't matter since this part is going to be covered by substrate anyways, but it was still frustrating..
There is a tiny bit of epoxy still left to do. The batch I had made while I was working on the sides was allowed to sit a little too long, kicked very quickly, and so it started to cure as I was applying it. This caused a few blobs on the side. I left that side as-is for now and will sand it down and re-do it once it's done curing.
I tried to make the front and top "show-room quality" by popping all the microbubbles I could find with a lighter.. haha. I went through a couple lighters doing this but am very pleased with how it turned out. I'll likely be covering most of the front with trim after it's installed in the wall, and the top will only be seen from inside the fish room, but I wanted to make this thing as nice looking as I could anyways.
I ended up using about 80% of the epoxy I purchased (although there was some waste).
There is a tiny bit of epoxy still left to do. The batch I had made while I was working on the sides was allowed to sit a little too long, kicked very quickly, and so it started to cure as I was applying it. This caused a few blobs on the side. I left that side as-is for now and will sand it down and re-do it once it's done curing.
I tried to make the front and top "show-room quality" by popping all the microbubbles I could find with a lighter.. haha. I went through a couple lighters doing this but am very pleased with how it turned out. I'll likely be covering most of the front with trim after it's installed in the wall, and the top will only be seen from inside the fish room, but I wanted to make this thing as nice looking as I could anyways.
I ended up using about 80% of the epoxy I purchased (although there was some waste).
Brian Crook
New member
And here's the rest of the photos up to current state. It's difficult to take photos of the detail work and edges because it's so dark, but I took one of the back edge and the overflow to give you an idea. The back edge is one 45 degree pour, however the reflection makes it look like it has two faces.
79chopperdr
I killed ALL that Coral!
Looks great! I'm enjoying watching this.
Alex IROC Z28
New member
Great work man.... I was just talking about something like that to my wife and she gave me the evil eye..... lol I wonder why!? lol.....
Wow! i don't know what I am am impressed with more, your skill and forethought that went into it or your craftmanship and attention to the most infinite detail! years ago there was a LFS that had done a few corner wood tanks in their shop which was in the basement of a late 1800's building. nothing square anywhere in this place!
first time i had seen wooden tanks. i really love the "anything size wise goes" with these tanks!
i will we watching this build 'til the end!
AG
first time i had seen wooden tanks. i really love the "anything size wise goes" with these tanks!
i will we watching this build 'til the end!
AG
rogergolf66
im an addict lol
How's the smell working with this inside?
CyclistMT
More Idiot Than Savant
Looking good! The fillets...are...AWESOME! It really is impossible to describe how well this epoxy works until you do it yourself.
The US composites stuff really isn't that bad. I did pours indoors in the middle of a MT winter and there was less VOC smell then if I had painted a room.
The US composites stuff really isn't that bad. I did pours indoors in the middle of a MT winter and there was less VOC smell then if I had painted a room.
Brian Crook
New member
Thanks everyone!
My experience working with this epoxy is the same as CyclistMT has pointed out. The smell isn't actually too strong, unless you mix a large quantity and allow it to kick before spreading it out. If this happens then it actually starts smoking and the fumes can get pretty frightening.. haha.. As I've mentioned a couple times though, I wore a respirator while working with the epoxy regardless. This was especially important while sanding down the epoxy and fiberglass, as the particles/dust is very fine and could easily be breathed in.
At this point I'll be doing some finishing touches on the epoxy while I wait for my glass to arrive. I also need to order the silicone.
CyclistMT, any recommendations on determining how much silicone I'd need?
My experience working with this epoxy is the same as CyclistMT has pointed out. The smell isn't actually too strong, unless you mix a large quantity and allow it to kick before spreading it out. If this happens then it actually starts smoking and the fumes can get pretty frightening.. haha.. As I've mentioned a couple times though, I wore a respirator while working with the epoxy regardless. This was especially important while sanding down the epoxy and fiberglass, as the particles/dust is very fine and could easily be breathed in.
At this point I'll be doing some finishing touches on the epoxy while I wait for my glass to arrive. I also need to order the silicone.
CyclistMT, any recommendations on determining how much silicone I'd need?
rogergolf66
im an addict lol
I just built a 72x18x10 glass tank. Was 2 tubes that go in a reg calking gun. If just the 1 pane of glass 1 tube will be fine
But
Having an extra on hand is nice. So get 2
