Cutting Starboard to fit (MegaFlow) Overflow Boxes

[Urabggr]

I'm gettting ready to cut my slab of starboard to fit my RR 120 AGA with twin megaflows and I wanted to see exactly what other people in my situation did. Since the megaflows are rounded, I'm probably going to have to copy the shape and then dremel it out. Are there any better ways to do this? Also, I plan on not cutting the 23" x 47" piece in half because I'm pretty sure that if I work it in right, I can get the starboard in in one piece. Anyone disagree? Thanks!

 

[javajaws]

A quality jigsaw would probably work better than a dremel. Make a template out of paper/cardboard first then trace it onto the hdpe.

 

[Karl K]

bump

 

[Urabggr]

Heh... funny that you should bump this because I actually just started cutting the board today (been pretty busy..). Anyway, incase anyone is curious, this is what I did. First I measured the back of the tank to find how large the overflows actually are and how far apart. They are 6.25" from the side glass, and 13.5" apart. The actual boxes are 10.5" each. After that, I traced the shape of the boxes onto a peice of paper by wetting the entire lip of the box and then pressing the paper onto it. This left an outline of the shape of the box in wetness and then I traced over it with pencil.

After all this, I drew the shape of what needed to be cut out where it needed to be cut out on the HDPE board. I started trying to cut with a dremel but soon realized that it wasn't going to work. Tomorrow, I'm going to borrow a jigsaw from a guy i know. I'll let you guys know how it works out.

 

[disbjohn]

jigsaw is what i used. use a plastic cutting blade and it works great. when i tried it with a dremel, it was overheating and melting the starboard.

 

[CSS Reef]

Dont think that 1 piece will fit due to the center brace and overflows but I just did this on the exact same tank. Came out perfect. Take some paper or cardboard and make a mockup template inside the the tank. Be sure to leave 1/2" gap all the way around the tank and overflows for the silicone so the board isn't laying on top of it. Take a table saw and cut out the rectangle portion. Then take a jigsaw and cutout the overflows sections. Last thing you need to do is cut it in half long ways. Very important do not cut from front to back because you will see the seam right smack dab in the middle of your tank from the front. No worries it will fit long ways. Your liverock will cover the long seam.

By the way if you are using genuine starboard (marine board) you should have no problems with melting etc... using standard woodworking tools.

 

[joshuaroot]

ok i am dumb whats starboard and whats it 4?

 

[kokob007]

Used for barebottom tanks. so you dont damage the tank, by falling rocks, etc.

link

 

[simion3]

I used a jigsaw for mine it worked way better than the dremmel.

 

[CSS Reef]

Pic

Pic

Here are some pics of the 1/2" thick starboard bottom..... Notice the long seam.

Hope this helps

 

[Conceyted]

i used a rotozip to cut around my overflow. I also sliced the starboard down the center instead of across like above. I made templates out of big sheets of brown paper and then drew the templates ont he starboard for precise cutting. came out just fine

 

[Urabggr]

I cut the starboard today and it turned out great! I used a jigsaw to cut out the overflows and then a circular saw to cut it in half lengthwise (great idea). I'll probably take some pics of it wwhen I put it in tomorrow. Gonna be a fun (and wet) day...

 

[Conceyted]

be careful adding it. it floats!