Bring on the CONE

[8mpg]

Note to self... It is probably cheaper to just buy a DIY kit, or just buying a decent skimmer. Dont really want to tally up the numbers...but so far:

Sedra 5000 = $85
Mesh mod = $7
Acrylic $60
Fleece and fiberglass resin $25
Scrap wood = free
-----------------------------
$170 and counting. Still need PVC parts, but those are cheap.

Cant really count the tool...but $90 on Dewalt Rotary tool (used to cut circles)

Right now Im making a fiberglass mold of the cone. I just didnt like the posterboard stiffness, so Im doing the subwoofer box building method of fiberglass.

wrap it in poylester fleece

Using spray adhesive

Scale to properly measure the resin. At $15/qt...its not cheap. But that is what you pay for when you buy at lowes. Would have been cheaper online.

I used about 7 ounces of resin for the fleece. Might need a 2nd coat. Its very absorbent.

 

[edthefishguy]

unless you are building a very custom cone, the cost of the avast marine kit is justifiable
plus the headaches of having to figure out all the measurements are gone

 

[8mpg]

LOL... round 2 = fail... Just cant fiberglass well inside a small cone. Next step is expandable spray foam. I just need a solid core. Hopefully foam will do it.

 

[jimmyj7090]

Hey, props to you for trying and documenting the process here

 

[EnderG60]

LOL... round 2 = fail... Just cant fiberglass well inside a small cone. Next step is expandable spray foam. I just need a solid core. Hopefully foam will do it.

HAHA why not just make it out of fiberglass(as in actual fiberglass cloth)?

Im getting my sister(teacher) to laminate some posterboard for me and Im just going to fiberglass right over that and install a small viewing window in it.

If you still want to make it out of acrylic, just do the above and sand the outside nice and smooth before you form the acrylic around it.

 

[8mpg]

HAHA why not just make it out of fiberglass(as in actual fiberglass cloth)?

Im getting my sister(teacher) to laminate some posterboard for me and Im just going to fiberglass right over that and install a small viewing window in it.

If you still want to make it out of acrylic, just do the above and sand the outside nice and smooth before you form the acrylic around it.

The polyester fleece worked well, but my problem was the fact that the fleece was supported and glued to the posterboard. I found out the hard way that fiberglass resin does not like to stick to posterboard.

The next trip up my sleeve (lol...dont know if you can really call it that) is a hot wire cutter and foam. Im 99% sure that this method will work. If I could just build a darn solid mold, Id go ahead and wrap it. I want a nice cone the first time around. I appreciate Jesse's pictures because it stopped me from just using the posterboard wrapped around the wood template.

If this thing ends up working, I might crank out a couple cones to play with different designs. I never thought it would be this difficult. Im confident on the acrylic part...just this darn mold.

Last but not least...if that doesnt work, I have a guy with a wood lathe that can turn down a solid wood buck mold. I just hate to outsource when its supposed to be a DIY project.

 

[Bamm Bamm]

Looking good man great thread and i've noticed over the years that guns and reefkeeping for some reason tend to go hand in hand at least they do in my house...

 

[108reefer]

Great build thread! I have considered doing something like this for some time - I would like to see the rest of the project come together as well, the bubble plate and plumbing. Nice job and keep up the great work!

 

[meco65]

My self I would go with the wood. If you buy PVC some one made that, some one made the acrylic, so it should not be a problem JMO.

 

[ERICinFL]

Fill the cone with plaster of paris, then wrap that with the felt. You don't need to glass the felt if you have a solid core.

 

[8mpg]

Fill the cone with plaster of paris, then wrap that with the felt. You don't need to glass the felt if you have a solid core.

well, the girlfriend is sick so no work on the cone today. Hopefully tomorrow. The next mold will be a solid core. We will see how it works tomorrow. Plaster of paris is a great idea. I have thought about it and if the idea I have now doesnt work, plaster it is

Thanks for the advice
Tim

 

[ERICinFL]

well, the girlfriend is sick so no work on the cone today. Hopefully tomorrow. The next mold will be a solid core. We will see how it works tomorrow. Plaster of paris is a great idea. I have thought about it and if the idea I have now doesnt work, plaster it is

Thanks for the advice
Tim

No problem. I had also thought of using a traffic cone, to pour the plaster of paris in. The inside of the traffic cone is nice and smooth and would probably be much better suited to hold the P.O.P.

 

[usctrack]

8MPG - complete tangent but I love the pup! I have 2 mastiffs myself! Along with 1 cat, 2 kittens, 2ea 90g tanks, a 24g cube and a 40B frag tank.

I am following along for the DIY ride. It always helps to learn from others and also have everyone else through ideas out there that might make it easier.

Good luck

 

[8mpg]

8MPG - complete tangent but I love the pup! I have 2 mastiffs myself! Along with 1 cat, 2 kittens, 2ea 90g tanks, a 24g cube and a 40B frag tank.

I am following along for the DIY ride. It always helps to learn from others and also have everyone else through ideas out there that might make it easier.

Good luck

Gotta love them. We have 2 mastiffs as we.. Both English Mastiffs. One male and one female. They are great great dogs...they just drool

 

[troylee]

here is how i do it.... this is a small version for a skimmer cup lid but the same way i do the big boys.....
from paper to finish product....

sheet metal mold....

heat your material and it should lay inside flawless if you did the layout right..

 

[8mpg]

Thanks for the pics Troy

Well, making the buck mold is kinda fun. Here is the current one. I will probably make a new one Thursday (clinicals all day tomorrow). Got 1" insulation foam from HD. Its pink panther brand. 4'x8' x 1". Plenty of material left to try and perfect this method.

After some research, a hot wire cutter seemed the best to cut foam. So I made a janky one with some safety wire (stainless) and a few boards and screws. Add that to a battery charger and viola...a hot wire.

Cut some 8.25" squares. I learned that the wire will stretch with the heat and become wobbly. So it was back to the hardware store to make tension screw.

Drilled a 1/2" hole and shoved a dowel rod in. Glued the layers together with foam/fabric glue

Sandwiched the foam with wood circles. 3" top, 8" bottom and screwed it together
Little trimming

End product. Not bad for a first try. THe wire keeps stretching. I have learned to cut slower and next time I will have a simple jig to hold the cone. I set the hot wire on the ground and moved the cone. This allowed for bad angles and the cone is not perfectly round. You can see the cut lines were not perpendicular to the base of the cone. Hopefully the next one will go better.

 

[troylee]

i take it your using that as a plug or male mold??? wrapping acrylic around the outside will never work.....

 

[8mpg]

i take it your using that as a plug or male mold??? wrapping acrylic around the outside will never work.....

porque?

That was the idea. I need a female mold? Im about to go crazy. I have seen a build or two where people use a plug to wrap acrylic around. Seemed ok. Didnt come out perfect like yours, but heck, they dont have an acrylic fab shop to work out of

Jesse showed pics of his on the first page that he wrapped around a plug mold. Little waves in it, but it should accomplish the goal. Id do a female mold out of roofing flashing but dont have any big enough to do it in one piece. Would be nice to have access a sheetmetal shop as well.

 

[frontosa_man80]

i take it your using that as a plug or male mold??? wrapping acrylic around the outside will never work.....

it does work, but like you know a male and female mold will have to be used. its more work but i helps it hold its shape and if the fit is good you get less waves and ripples.

-jesse

 

[ERICinFL]

here is how i do it.... this is a small version for a skimmer cup lid but the same way i do the big boys.....

Show off! :lol: