Custom 210 gal. in-wall build with steel stand and DIY rock walls

ReefWhatYouSow

New member
Hey Everyone,

So, this is my first big build, and I look forward to hearing your feedback and any tips you have along the way. I first want to say that I no way could not have done this by myself, and there are many individuals that deserve credit; from family and friends, to my online community and local reef group (Tampa Bay Reef Club). I have wanted to start a build thread for a while, but with many long hours being spent on the build I haven't put any effort towards the thread. A lot of time and money has been put into the project, and I'm coming to the end of my budget with a little more to go on the build. I guess that is how it is for all of us, and I will be looking to get an extension on my credit line soon! Lol"¦ It has also taken a while to get to the point I am at now. A weekend here and there, as well as some long nights has been my progression. Last week I worked every night till about 2:00am and then got up at 6:00am for work.

A little background on how I came up with some of my concepts and ideas"¦. Being newer to the hobby I have had to research just about everything, which I have enjoyed. There seems to be many options to how something is done and not so much a right or wrong way. I've decided to take ideas from other reefers and make them mine.

First, I have wanted an in-wall tank for years and now that we have a home with a huge closet in the middle of it, what better way to utilize the space than with a mini fish room! The size of the wall determined for us what size tank we would be able to get, but I didn't want that to keep me from getting a large volume tank. I knew that it would most likely need to be a custom tank which financially discouraged me. Not long after joining Reef Central a custom tank popped up for sale in Pompano, FL and jumped on it. It did entail a day journey from Tampa, FL to go pick up the tank, but I am still impressed with my savvy shopping and luck on that one.

The tank is 60" long x 27" deep x 30" tall with euro-bracing up the wazoo. The glass is half of an inch thick and I have a large mid-center overflow. If I remember correctly it was built by Exotic Aquarium.



Now, I've seen a lot of great tanks. Some have the minimalist look and some are throwing up coral. I enjoy a natural look with a twist. At the same time, there are things that I like or find beneficial that I would want in the tank as well. I enjoy going to the aquarium and trying to steal ideas from them. Their budget may be a little bigger than mine, but at least I can get ideas, right?

I chose to go with a DIY rock wall surrounding the walls of my tank, as well as surrounding the overflow. Now, I have seen a lot of different makes of a rock wall, and there has been a little controversy over how long it will last in a tank, but this is probably one of the things I'm most excited about going into the tank. I have seen too many walls that have a fake look, or at least they do until they start getting covered by coralline algae or corals. I wanted to make this one look as much as a rock wall as possible so I didn't scrimp in this area. I used a couple hundred pounds of rocks, sand, and crushed coral in this build. The rock type was a mix between marco, tonga, and I think some various pieces of pukani and something else. I also used black pond foam and epoxy to keep things against the egg crate. You will see in the pictures that I made a mock tank to size out of chip board so that I could play with some ideas without scratching the tank.








You will also notice a few oddities when looking at the egg crate cutouts. One thing that you will notice is that I cut pieces for the back corners that will angle. While this makes the tank look a little smaller, I have created various caves, as well as an area that I can siphon from, etc. I am also using this area to hide a powerhead in the back right corner. You will also notice that I have wrapped pvc pipes around the overflow. I will have a closed loop system pushing water out of the rock wall that surrounds the overflow. Unfortunately, I can't take credit for this idea"¦ but I can say that I'm pretty sure that I have exceeded my own expectations with this.








 
The rock came in all different sizes and shapes (as it should be) and if it was left in its natural form it would definitely take up too much space in the tank. So to leave the natural look of the rocks, but not utilize as much space I cut the majority of them in half using a diamond blade wet saw. It was like cutting through butter. Now, I was definitely sore from the squats that I did throughout the day.














 
Even after reading other reefers caution about the pond foam expanding I was surprised by the amount. It didn’t seem to throw off anything, but just a surprise. Adding the rock was much like a puzzle, but it also allowed me to put some of my own taste and ideas into it. I tried to keep a natural look, but made sure to stick in pieces that created little shelves and caves. I used mostly big rocks towards the botton and smaller ones at top, but I did mix it up a bit so it didn‘t look so “staged”. Once my larger pieces were down I filled in gaps with smaller pieces.

I started with the wall surrounding my overflow which will have a closed loop system. I drilled holes into the pvc and stuck in small tubing so the holes would get filled in with foam or epoxy. Later I will be pulling out all of the tubing and my hope is that since water will constantly be flowing out of the holes nothing will grow on top of it. I am also going to make the close loop system on an automatic variable speed pump, but more on that later!













 
Note the little burned spot on the foam. This stuff is definitely flammable lol… A nearby citronella candle caught some of the fumes and also caught us by surprise!












Some of the foam went through the backside of the egg crate. I had to cut it off to make sure that it will lay flat against the glass when I adhere it.




Once I started adding sand it started looking 10x better. You could really start to see where it was going.







 
Now, even though people have use the pond foam without issues of chemicals I wanted to let the rock walls sit in a pool of water to let the chemicals leach out of the foam, as well as the rocks since they were recycled from others' tanks. The goal was to do 3 weeks and then drain it all, and then do another 3 weeks. I think I am going on 6 weeks, so I really need to drain it. And do it again before I am done with the build.






While the rock walls were soaking, it was time to work on another section of the build which is the tank stands. This is something that I did as much research on without hiring an engineer. I'm not going to say that there were not accidents made, but everything was workable and I still have all ten fingers and toes. I'm a happy guy. I went with 1.5 inch square steel tubing. I chose steel mainly because it allowed me more space in the room and I also like the look of it. It does come at a price however. I think I spent a little more than $300 on the steel from Alro Metal in Tampa, and a fellow reefer (toddmau) and I did the work. He's the reefer and I'm the guy who measures. Don't ask how that went lol"¦.

The large stand was made to where a lip would be extended the depth of the wall. I also had to make sure that there was room for my sump on the bottom, and a frag tank in the closet. Luckily it all worked out in the end! A lot of people go with a powder coating the stand, but it isn't cheap so I went with a Rustoleum primer and a Rustoleum spray paint. I personally love the color of the stands. It's a bright red. If anyone wants the name, I will be happy to get it for you.











 
The next stage of my build was cutting the hole in the wall where the tank was going. I wish it was as simple as that! Fortunately/unfortunately the wall where the tank now sits is a load-bearing wall. So we had to do a little more work to the wall by providing extra support along with a header and footer. Since it is my bedroom directly above it I wanted t make sure it was nice and secure : )

I got the okay to proceed from my wife with the promise that things would at least be pretty on the outside by Thanksgiving. My dad worked with me on those late nights to get this construction done prior to Thanksgiving. We had to start with the electrical. We moved some switches to another outside wall of the closet, moved an outlet up high on the wall (my Ecotech lights will plug in here), and then piggy-backed off another outlet to give two additional outlets in the closet. We also made everything GFCI for protection. We have power and we didn’t burn anything!










Before cutting anything, we made a temporary wall that went on the outside of the closet to give support to the ceiling above while doing the work. You can see it through the hole that we cut. There are as many studs added to the temporary wall than what are being cut out. We took this same concept when working adding the support to the actual wall. You want to be sure that you add as much support as you take out, if not more (from the research I did prior to the job).



 
While working in the room we also ran through the ceiling one waterline, one airline, and one electrical cord. The waterline will be bringing in my freshwater and salt water. The airline is to bring in outside air to the skimmer air intake. The electrical cord will connect a pump to the Apex system that will be pumping in the water from the garage.

We used a mold resistant drywall to replace the old, and then I used a mold resistant primer as well. Then I used a high gloss Behr paint so it would be easy to clean if I ever made any messes in the room. Now, as far as the color goes"¦ It isn't what I expected, but it is growing on me. It has started to remind me of the Florida Keys.
















 
I added a rubber underlayment to the floor for a little grip and easy way to clean/hide spills.




We brought the stand in and soon after we brought in the tank. We used four guys to bring it in and get it up on the stand, but I am sure that we could have used less. I liked having the 6 guys though. The tank was set on a half inch piece of foam that laid on a half inch piece of plywood. We put the tank in long ways and then spun it around to fit the stand. My measurements were at least good enough that everything fit in the hole with a little bit of wiggle room.








I’m going to follow this up with more pics of the tank being put in and then start trying to stay more current with the build for everyone. I’m hoping people can use some of my ideas, learn from my mistakes, and share some of their own. Thanks for being a part of this!
 
Nice! I love how well you have documented this so far. I did a foam rock wall in my 135 and now have a small one in my zeroedge. You will love the wall. Keep the pics flowin
 
Nice build! I did a rockwall on mine and it was definitely worthwhile. I used the same method, but smaller rocks, each ziptied to the grate. It makes my 125 seem deeper and I have openings in the rockwork to let light shine behind. Makes for good swim throughs and I can see the fish swim in front or behind the rockwork for the entire length of the tank.
 
Sweet job. You had explained what you were doing when I stopped by but this has turned out better then I thought.
 
Thanks everyone! This has been a lot of fun and I'm looking forward to getting more work done this weekend. I'm also glad to hear that you all are enjoying you rock walls. That is probably what I am looking forward to most in the build. Hopefully I will have time this weekend to move this project forward, and don't worry"¦ I will be sure to take a lot of pictures.



Below is the continuation from where I last left off. Enjoy!










The crew"¦




Everybody's doing it"¦





Now, I had trouble finding trim that was more than 6.5 inches to cover the bottom gap so that is what I went with. It actually didn't turn out bad, but I didn't account for the water level (stupid mistake). I also wouldn't mind more of the bottom to be covered so you don't see the sand against the glass. My plan is to add a piece of trip surrounding the inside of the first piece of trim. I'll probably use a dowel to hide where they come together and thus making my own decorative trim.







You may notice the rope look on the trim. That is something that I added to pull in some nautical theme. I actually didn't use any nails in putting this up, but instead pushed the tank out just a little bit and adhered the trim board to the tank using power grab. I then used caulk around the outside of the trim that was touching the wall for a seamless look.

I received many compliments on it during the holiday, so I'm hoping that I can make the inside look as nice as the outside. I have very little knowledge on plumbing the tank so I'll possibly be moving a little slower to make sure that I do it correctly. I'm going to have the 30gal frag tank connected to the DT, which will be connected to the sump. I'm also planning to run everything through 2 single reactors and I was thinking about running everything through another tank for either a remote deep sand bed or an oyster tank (with one or two oysters to start off). If anyone has suggestions of some good threads to review, please feel free to share.
 
Yes not a good time to text back. I will try and get with u today. Sunday may work out. Let me talk to the wife. Do u have all the plumbing parts u need? I can get them at whole sale prices too.
 
Yes not a good time to text back. I will try and get with u today. Sunday may work out. Let me talk to the wife. Do u have all the plumbing parts u need? I can get them at whole sale prices too.


No problem. I have pretty much everything. I might need a bulkhead for the frag tank and I was thinking about adding a 20 gallon as an anemone tank to the setup. Would you be able to put a hole in that. If I remember right you said that you have the tools to cut glass?
 
Yes i can cut the tank for u. What size bulkheads?


I'll have to check when I get home, but I will need two for my barrels in the garage, one more for the frag tank, and one for the anemone tank. I plan on having that tank (20gal) below the frag tank and the water can flow down from the frag tank to the anemone tank, and then out the anemone tank to the sump. Thoughts?
 
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