Bulkheads: the good, the bad, and the ugly...

Sk8r

Staff member
RC Mod
I have a wedge Oceanic 54, with a factory-installed reef-ready downflow box at the apex. I had a bulkhead fail, and start leaking onto the livingroom carpet and into the basement. It's a slow leak---bulkhead failures usually are, but they have ways of becoming bigger and bigger ones fairly fast.

a) it's Monday. You can get bulkheads from a good lfs...but they tend to be closed on Monday. You ought to be able to get them from a good plumbing supply. Mine, best in the region, said, "A what?" when asked for a 3/4 inch inner-diameter/1 inch outer diameter bulkhead or gasket. Thank goodness the local *hose* warehouse had one...and knew instantly what I wanted.

b) factory installed bulkheads can be skimpy on plastic. IE, just TRY to get a good Channel-lock grip on a screwed retaining ring 1/4 thick. We could not get it loose. There is a marvelous little saw that consists of an oblong ring with a blade, and the handle can be moved all around the ring to let you work at almost any angle. We sawed the side off that cursed retaining-ring on the bulkhead bottom and then could extract the old bulkhead from the hole.

c) installing a bulkhead requires an immaculate surface, or you can't trust the seal. Try to get that in a 4 year old sump with crud all over. But we did: two cinderblocks made a way to stand high and work inside that corner downflow.

d) tighten as far as a strong guy's finger-tightening goes. The LAST thing you want to do is crack that glass bottom.

That's about it. But let me tell you, respect bulkheads and treat them gently. Replacing one is a 4 hour job in cramped spaces. If you accidentally break the glass, you're in it for a new tank.

Thanks to the double-walled downflow box of an Oceanic, however, we could completely drain the downflow while the tank is nearly at full water level, and we could work back there with no disturbance to the inhabitants. That double wall is worth a lot. It's an S cuve of a water route that will not let the tank drain down more than the top of the (shorter) inner wall. Nice.



This was not how we planned to spend our day. But
 
OTOH, I've had siphon adventures, too, with an external box, that involved water over the side.
 
OTOH, I've had siphon adventures, too, with an external box, that involved water over the side.

LOL, I have heard these stories Sk8r, I just don't get it, 16 going on 17 years now & I have never had a siphon problem, now I did have a flood once cuz of Mr. Kitty!!!, he knocked off a return line whilst I was working, never again without hose clamps!!! Also I recommend putting siphon break on all returns, even though you should always be sure your sumps or wet/dry's can handle a power outage. Thanks, again.
 
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Same here, never had a RR or drilled tank. I've used HOB overflow boxes on all of my tanks, 20 years +. I've never had a flood, not once. Maybe I just take more care than most, or been lucky?!?! (knocks on wood) To each his own, I guess. JMTC & GL!
 
We had more than one (siphon box) in freshwater tanks and had no end of trouble: it was either losing siphon (frequent powerouts in that town) or clogging and losing siphon, or somebody tweaking it and making a mess, so our usual problem was no siphon at all---hardly a week went by but what we had to restart a siphon on one, or all, of our tanks; but on another occasion, as I mostly recall the mopping---it was a hose coming loose. Perhaps modern siphon arrangements have sturdier plumbing.

I've had external pumps and downflow arrangements on my marine tanks, and this is the first trouble---this particular tank, bought in 2004, moved in 2007, and heavier than sin, (83 lbs empty, and it had to be entrusted to movers with those fragile bulkhead connections resting on the best support I could devise for it) has had its problems, notably the expired calcium test that I didn't catch until I had calcium deposits throughout all the hoses---and this is a basement sump. So It was no little problem! We think the bulkhead problem actually stemmed from that. We also have a line running 'slow', and we're flat going to replace that drain line all the way down to the sump, with 'hard' pipe instead of hose. Wish us luck!
 
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I by accident pulled on one of my drain pipes the other day and managed to losen up my bulkhead. Luckily, the rubber did not move and the leak was minor and stopped with just a retightening of the bulkhead. What fun. I really dread if I had to replace one of these. Getting the overflow box empty. Getting some sand out that has collected in the overflow. Plus a very small akward place to work in. Probably not as hard as i think it would be, but still not fun. Maybe I should order a spare set of bulkheads now that you mention it.
 
Sounds like a good weekend project sk8r!! I fortunantly don't have that much plumbing work with on my 125 gallon. Both the tank and sump are in the basement so I can't do what you have lol. I did however have a bulkhead leak when I first set up the tank. Made the 16 hours it took seek even longer! GL with the plumbing replacement!!
 
What really helps is being female. [Small hands, fit in places a big guy's just won't.] A corner wedge downflow is not for football linebackers. But if it wasn't for that weird little saw I picked up just because I never saw the like (Lowe's) I'd still be swearing at that retaining ring. The replacement has a nice 1/3 inch thick ring you can easily turn. But the fact the rings turn opposite what you expect, and the fact it was put on at the factory, probably by a robot, with JUST that size instrument, was just not giving us any joy. The ring we got off was scarcely 1/4 inch, and flimsy. But tough. Very tough!
 
Sk8r, so can you be hired to get your small hands into a 4 inch overflow? My tank has one of those center low profile dual overflow/return setups.
 
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