DIY 90 gal stand w/55 sump

[countertopguy]

Hey guys,

I thought I would share the construction of my DIY stand. I know others have done this but I thought I would chime in as well.

My plan was to build a stand that would hold my new 90 gal AGA tank and allow me to use my existing 55gal as the sump.

I started by searching reefcentral and studying what others have done. I really wanted to use a "furniture design" approach. (no 2x4's). The problem I ran into was the 55 gak sump below. In order to access the sump and remove it if necessary I needed to install openings at each end of the stand. I felt it became necessary to go the 2x4 route if for nothing else, peace of mind.

I began the design process by sketching out the structure.

This image shows the internal 2x4s as well as the plywood back, top and bottom shelf.

I chose to make the stand slightly deeper than the 90 gal tank so that the stand can rest against the wall and all the plumbing and electrical will be hidden.

This image shows the stand with the cherry face frame stock applied to the structure.

The cherry stock is 3/4" thick and will be finished to match the decor in my house. I also plan to make raised panel doors to finish off the stand.

This is the final image showing the stand with the tanks in it and on it. These are standard 90 gal and 55 gal AGA tanks.

I have finished the 2x4 structure and will post photos later today. The next thing is to install the plywood.

Thanks for looking.

Steve

 

[countertopguy]

Well it has taken me longer than anticipated to get these posted but here goes

Here is the beginings of the stand. This is the bottom portion prior to the legs being attached.

Here are the leg structures glued up and ready to be attached to the base. These are upside down.

This is a shot of the structure with the front and back leg assemblies installed.

And finally the bones of the stand are complete.

You'll notice I've framed the stand to support the tank on its edges. The stand is about 8" deeper than the tank.

Next I'll post some pictures with the plywood and the primer.

Steve

 

[countertopguy]

OK here is the stand with the plywood and the primer.

It starting to look like the original sketch. Still need to add the face frame and doors. Am thinking about spanish cedar instead of cherry.

This is the beginning of my power center.

I am installing switches on one side and outlets on the other.

It will fit into the stand like this...

I plan to have another on the other side that will operate the lights. Once the faceframe is added and the doors are put on the switches will be hidden from view but allow me to turn off and on equipment easily.

Anybody have any input on the wiring. (like how do I do it?)

Thanks

Steve

 

[CIMulation]

More pics of progress please!

 

[countertopguy]

Here is the progress so far on the power center. Many thanks to Lunarcubes for his help with the wiring.

Front

Back

I still need to prime and paint the wood and install the covers. I'll wire this to a plug and it will fit in the side of the stand. It will be removable if I need to add additional outlets.

I plan to make a similar power center to house the outlets and timers for the lights.

Next up is the face frame construction for the stand.

Here is the wood I am using.

It is spanish cedar, a cousin of mahogany. It finishes like mahogany but is a bit cheaper.

I plan to start on this tonight so hopefully I'll Have more to share soon.

Thanks for looking.

Steve

 

[countertopguy]

Sorry for the delay in the progress of the stand. I don't know how many are following this, but posting the progress is helpful in keeping the project moving forward.

I have begun to work on the face frame of the stand. This is the "outer skin" that will cover the 2x4 frame. I am using 3/4 spanish cedar that was milled from 4/4 stock. I am still debating what type of finish to apply. I'll have more on that later.

This is a shot of the Face frame for one end of the stand.

I used pocket screws and glue to hold everything together. It is amazing how strong a joint you can get with the pocket screw system.

Here is a shot of the tank from the front

And one from the side

In this picture can start to see the beauty of the wood. It has a subtle grain that is very striking.

I have the tank on the stand so I can fit the face frames to cover the plastic trim.

Stay tuned...

 

[AnnArborBuck]

You are doing exactly what I have been planning. Keep the updates comming!

 

[corb66]

keep the pics coming. I am also planning on a new setup and it is nice to see yours..

Do you have the sump yet?

 

[countertopguy]

corb66-

I am planning to recycle my current 55 gal to use as the sump. I'll add baffels, etc. to create a skimmer section, fuge, and return.

The size of the 55 has been a major determining factor in the design of the stand. Since both tanks (90 and 55) are the same length fitting one underneath the other in the same stand required some thought.

thanks for looking.

Steve

 

[countertopguy]

updates!

updates!

Well I finally managed to find some time to get back to work on the stand.

I have been mainly focused on the electrical work. I have made two power centers that consists of oultets controlled by plugs. Many on RC have done this. My stand will have 2 (one on each end) allowing me to split the systems in case of a tripped breaker, etc.

Here is the outside shot of one

keep in mind the face plates have not been added yet and the finished product will get a door to hide the switches. The Power center will be in the same position on the opposite side.

On the inside of the stand I wanted the plugs to be protected from splash etc. I made this -

This shot shows the cords...

and this shot shows how you access the plugs

The entire unit is hinged at the bottom to allow access to the plugs.

I need to figure out a way to "seal" off the hole where the wires go in.

I need something flexible that will allow the cord and plug to go through but keep the moisture to a minimum.

I thought about these...

But I haven't been able to find them in the right size. (1 1/2 " dia)

Thanks

Steve

 

[countertopguy]

Some Updates

Some Updates

Well it has been a while since I have had anything new to report and what I have doesn't look like much. I have managed to attach the face frames to the 2x4 structure.

This looks like a previous image but the frame is now sanded and attached, ready for the trim and doors. The empty spot on the power center will get two hard wired timers to control MHs, PC, moonlights and fans (if needed)

I wanted to make certain the interior was sealed and all the woodworking was completed before I made everything permanent.

Here is a shot of the left side of the stand.

(I have made two power centers that will run off separate outlets. Each is mounted on hinges that allow the power center to be tilted forward and serviced.)

This is another shot of the inside of the stand.

This is a structure that will shield the power center from splash and salt creep. I used pond liner to cover the cord holes. It doesnââ"šÂ¬Ã¢"žÂ¢t look that good but it should work pretty well.

Hopefully next time weââ"šÂ¬Ã¢"žÂ¢ll see some different things. I am starting on the hood and the trim next. I am going to try to make cove moldings on the table saw.

I haven't gotten a lot of comments on this thread. Feel free to let me know what you think.

Steve

 

[countertopguy]

overdue update

overdue update

Sorry it's been so long since my last post but I've had other projects that have been getting in the way of the stand construction.

I managed to make and install the drip edge trim to the stand

and another shot

This doesn't look like much but it required me to run the bullnose on the router table rip the piece to width, cut the miters and install. This piece adds a finished quality to the stand top of the stand. I plan to add a piece of trim below it to breakup the large amount of space between the top and the doors (and conceal the screws) . However, this will have to be done tonight because I ran out of wood and will need to get more today.

I was also able to get started on the hood. Here is a shot of the frames for the front and side

These frames will receive a panel and are constructed like a flat panel door. The panels are made from re-sawn lumber that is cut to 5/16 thick. I ran into a problem because the panels after being resawn started to cup. I am hoping they will flatten after they have acclimated to the shop.

Will post more soon

Steve

 

[countertopguy]

more updates

more updates

Well I got a little more work done over the weekend.

I started work on the hood.

Here is a sketch of the design

Basically it is a pretty simple flat panel design. The entire front is hinged and will swing up and sit on the top of the hood. I also plan to have a hinged section on the top that the lights will be mounted to that will allow me full (or as much as possible) access to the tank without removing the hood. One thing missing from the sketch... I plan to add a bullnose molding around the top and bottom to tie the hood in with the stand. (I owe much of this design to thrlride and the log of his tank build. http://www.reefcentral.com/forums/showthread.php?s=&threadid=569250

Here is a shot of the panels that will soon be the hood

The panels, as I mentioned before, were resawn from thicker stock. They warped a bit after being cut and I was concerned that they might not work. But they seem to be fine once they were mounted in the rails and stiles. I have applied a few coats of finish to the panels prior to gluing up the frames. Once the frames receive the finish the color should be consistent. Although I like the two-tone look. Might have to remember that for a future project.

Here are the doors for the stand.

Like I mentioned the color will be consistent once I apply the finish to the rails and stiles. I am using a tung oil finish that will seal the wood and give the grain a lot of depth. Tung oil finish is easy to apply, resistant to water and chemicals and easy to repair.

If your paying close attention you'll notice two of the doors are missing from the shot. I measured wrong and have to remake two panels

Thanks for looking will post more soon.

Steve

 

[mattydub]

great work...too bad that cherry's going to be ruined in no time! Nuttin holds up against salt water! Really neat DIY work though...

 

[The Shrimp X]

Ok I love the design of your stand!!!!!!!!!! Iplan on using it for the design for my 90, if thats ok... But have a few questions. 1st do you have one plug that leads from an out let to the tank out lets? I am a little confued. Also do you have the plugs leading to an out let or did you have to like drill throught a wall to get another power supply? And last, can you upload the pics of the front, back, and wood that you are using?


thanks for all the help, i love this design, it seems to make life much easier!!!

 

[AfAqua]

That's flippin awesome! Don't stop posting when the stand, hood etc are complete. Take us through the entire project.

 

[countertopguy]

great work...too bad that cherry's going to be ruined in no time! Nuttin holds up against salt water! Really neat DIY work though...

I hope not. My current stand is pine (AGA Stock) and I refinished it 2 years ago. It has held up fine.

Ok I love the design of your stand!!!!!!!!!! Iplan on using it for the design for my 90, if thats ok... But have a few questions. 1st do you have one plug that leads from an out let to the tank out lets? I am a little confued. Also do you have the plugs leading to an out let or did you have to like drill throught a wall to get another power supply? And last, can you upload the pics of the front, back, and wood that you are using?

Thanks...feel free to use anything you see. I have taken much inspiration from others on this site as well.
As far as your questions go... I chose to make power centers instead of using the DJ units that others have used. There are two seperate power centers. Here is the one on the left side of the stand. (the empty space to the right is where the 55g sump will be.

It is hinged at the bottom to allow it to swing out

to access the plugs from the pumps etc.
http://allservico.com/gallery/data/media/71/P6120686.JPG

In this image you can see the yellow cord at the bottom. It plugs into a dedicated wall outlet and provides power to all the outlets on the power center. Each outlet on the PC is controlled by the corresponding switch. my thought was this way I can cut off pumps, lights etc without unplugging.

Here you can see the power center from inside of the stand.

Here you see the cover that protects the outlets from moisture and salt. It's hard to see, but the black membrane is actually pond liner that I epoxied in place. I cut slits in it so that the plugs from the pumpsetc can fit thru, but be reasonably protected.

Hope this helps clarify some of the electrical questions.

Steve

 

[countertopguy]

Sorry- Double post was trying to edit an image and ended up posting twice.[
QUOTE]great work...too bad that cherry's going to be ruined in no time! Nuttin holds up against salt water! Really neat DIY work though...[/QUOTE]
I hope not. My current stand is pine (AGA Stock) and I refinished it 2 years ago. It has held up fine.

Ok I love the design of your stand!!!!!!!!!! Iplan on using it for the design for my 90, if thats ok... But have a few questions. 1st do you have one plug that leads from an out let to the tank out lets? I am a little confued. Also do you have the plugs leading to an out let or did you have to like drill throught a wall to get another power supply? And last, can you upload the pics of the front, back, and wood that you are using?

Thanks...feel free to use anything you see. I have taken much inspiration from others on this site as well.
As far as your questions go... I chose to make power centers instead of using the DJ units that others have used. There are two seperate power centers. Here is the one on the left side of the stand. (the empty space to the right is where the 55g sump will be.

It is hinged at the bottom to allow it to swing out

to access the plugs from the pumps etc.

In this image you can see the yellow cord at the bottom. It plugs into a dedicated wall outlet and provides power to all the outlets on the power center. Each outlet on the PC is controlled by the corresponding switch. my thought was this way I can cut off pumps, lights etc without unplugging.

Here you can see the power center from inside of the stand.

Here you see the cover that protects the outlets from moisture and salt. It's hard to see, but the black membrane is actually pond liner that I epoxied in place. I cut slits in it so that the plugs from the pumpsetc can fit thru, but be reasonably protected.

Hope this helps clarify some of the electrical questions.

Steve

 

[countertopguy]

more updates

more updates

I got some time last night to work on the hood.

here it is closed

and open

here it is on top of the tank. (no front because I need to install the bullnose trim and hinges

and here from the side

finally here is a close up of the side of the hood. This shows the cuts made to form the lip to allow the front to rest on the top when open.

got a little sanding to do here and it will be ready for the finish.

Next up- the hood top and bullnose trim and hanging the doors.

Steve

 

[jaze36]

Nice work, its great the way you hooked up the switches and the plugs. I am doing that on my next stand!!!, Thanks for sharing and keep up the good work.