Foam/Rock Wall for my 265 gallon Tank!

<a href=showthread.php?s=&postid=14145430#post14145430 target=_blank>Originally posted</a> by jherrin215
How much time did you actually spend on your wall grouper?? Also how did you apply your epoxy to the wall once finished?? I want to make sure if I do this it's right and not something I'm going to have to worry about down the road. Thanks!!
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Hmmm, a few weekends for sure, maybe 4? After I did the foam, I let it dry real good. Then I mixed the 2 part epoxy and brushed it on with a cheapy Home Depot brush (the brush will be useless after one session, so buy lots). Immediately douse it with sand or whatever you are going to use. I also brushed the backside with just Epoxy to be on the safe side. Then 2 weeks drying and in the tank it goes (providing it still fits and you don't have to start chopping and trimming like I had to do).

It's not that hard and a lot of fun, you will find that you get bolder as it progresses, remember, BIG rocks, and lots of them. I also used a cut up small Pepsi bottle and tied rocks around it for swim through caves...
 
work of art

work of art

Now! I am lost for words and trust me I sat down on my day off and went through the whole thread reading every single comment made and replies from yourself.

We here in the UK are far behind you Americans lol.... Great work and I will be trying to do something along the same idea and design of yours. You deserve a salute and I bow down to your great skills and thoughts which have gone into this whole project.

I am still little bit confused regarding gluing the sand onto the exposy. Please would kindly tell me how and what type of reef save glue are you using and are those entire sip ties are reef safe too. I know they are well embedded behind the exposy but still would like to know so I buy the right ones.

Thanks for your inspirational thread and I hope you enjoy your tank.

Thanks
 
I think I want to try this for my new 90g. My current 55g was mostly DIY rockwork with quickcrete and sand. It took a good while to cure before it was useful. My tank has been drilled for a closed loop and I wondered if the bulkhead fittings would hold a structure up without trying to silicone it to the tank? There would be no weight on the bulkheads and fittings just use them to balance the structure. Anyone tried that?
 
I Purchased the majority of the materials today to start building my wall (Rock, foam, eggcrate, and zipties, still need to order the epoxy resin)!!!

Its cold outside however, and I am concerned about using the Z-Poxy indoors. Any tips on this? I have read various other posts that claim that you can actually bond the sand to the foam. I may try this to see how well it works out, but I would hate to have the sand fall off after the wall is completed and installed.

I cant wait, this is going to be fun!

Scott
 
Just got my 50lbs figi marco rock and 20 lbs of rubble in yesterday. Im gonna "maybe" start wall tomorrow but im still trying to figure out what sand to use. i thik i got way to much rock though..... 48x18x12" tall!?
 
<a href=showthread.php?s=&postid=14168312#post14168312 target=_blank>Originally posted</a> by tahiriqbal


I am still little bit confused regarding gluing the sand onto the exposy. Please would kindly tell me how and what type of reef save glue are you using and are those entire sip ties are reef safe too. I know they are well embedded behind the exposy but still would like to know so I buy the right ones.

Thanks for your inspirational thread and I hope you enjoy your tank.

Thanks
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Thanks for the compliments. You do not use a glue to attach the sand, the epoxy IS the glue and zip ties are plastic, so no problem.


<a href=showthread.php?s=&postid=14168870#post14168870 target=_blank>Originally posted</a> by oldsaltman
I think I want to try this for my new 90g. My current 55g was mostly DIY rockwork with quickcrete and sand. It took a good while to cure before it was useful. My tank has been drilled for a closed loop and I wondered if the bulkhead fittings would hold a structure up without trying to silicone it to the tank? There would be no weight on the bulkheads and fittings just use them to balance the structure. Anyone tried that?
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I think the bulkheads will support the structure but make sure there is no weight on them whatsoever.

<a href=showthread.php?s=&postid=14174824#post14174824 target=_blank>Originally posted</a> by THEUNION1
What kind of sand do you use? I mean people dont buy live sand and dry it out im sure.....
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I used dry Carib Sea aragonite sand, it's very coarse and works very well for this application. I also had some crushed coral that I mixed in.


<a href=showthread.php?s=&postid=14174874#post14174874 target=_blank>Originally posted</a> by atlantiscoral
I Purchased the majority of the materials today to start building my wall (Rock, foam, eggcrate, and zipties, still need to order the epoxy resin)!!!

Its cold outside however, and I am concerned about using the Z-Poxy indoors. Any tips on this? I have read various other posts that claim that you can actually bond the sand to the foam. I may try this to see how well it works out, but I would hate to have the sand fall off after the wall is completed and installed
I cant wait, this is going to be fun!

Scott
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I remember there was something in the instructions on the epoxy about the suggested temperature it needs to cure in. If you use it inside, I’d make sure it’s in a well ventilated area, but should be no problem. I don't remember it smelling too bad. The sand will stick to the foam aswell, but I think more will come off in the long run. Even with the epoxy, some will come off for a while.

Don’t cut corners, you are doing this only once and might aswell do it right!


<a href=showthread.php?s=&postid=14175579#post14175579 target=_blank>Originally posted</a> by THEUNION1
Just got my 50lbs figi marco rock and 20 lbs of rubble in yesterday. Im gonna "maybe" start wall tomorrow but im still trying to figure out what sand to use. i thik i got way to much rock though..... 48x18x12" tall!?
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Be generous with the rocks, I started out with little pieces and got bolder as I progressed. I ended up doing my first piece over and put triple the amount of rock I started out with.

It is great fun seeing it all come together. I have coralline algae all over it now, little feather dusters and even some aptaisias. It looks very natural and the possibilities of attaching frags are endless.

I’ll find some close up shots in a bit.
 
<a href=showthread.php?s=&postid=14185373#post14185373 target=_blank>Originally posted</a> by sixspeed
speckled, where did you purchase the epoxy from?
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I bought it direct from Bob Smith Industries, but any Model Airplane Hobby Store should have it. It does NOT go very far, so if you think you need 3, buy 6! I think I used 19 sets :eek1:

In case anybody wants to know about the foam, here is the link
http://www.touch-n-foam.com/wheretobuy.php
 
ok, thanks speckled, i ordered two sets. I am only using it for a small island and a corner of a 40 gallon breeder. hopefully i got enough.
 
<a href=showthread.php?s=&postid=14185980#post14185980 target=_blank>Originally posted</a> by Speckled Grouper
I bought it direct from Bob Smith Industries, but any Model Airplane Hobby Store should have it. It does NOT go very far, so if you think you need 3, buy 6! I think I used 19 sets :eek1:

In case anybody wants to know about the foam, here is the link
http://www.touch-n-foam.com/wheretobuy.php
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Ok, now I am confussed.

Kannin stated he only used 1 x 12 oz kit for his entire project! I know you did the entire back of your wall, but I am just trying to figure out how he got away with only using 1 12 oz kit!!!?!!??

Because of the cost I have been researching alternative methods & choices of epoxy resin. Seems like there are many alternatives to this, I think AES (Aquatic Eco Systems) sells a Epoxy Paint (and PPG also has a epoxy paint called AquaPon) and various other Marine grade 2 part epoxy's are available (West Systems, and MAX ACR just to name a few). If I am going to need a lot, purchasing in bulk (1 Gallon+) is going to make more sense!

I think coating the back of the wall with epoxy resin is a good idea... and in my application almost a necessity since the tank is acrylic, I am going to need a surface that is bondable to acrylic (i.e. the epoxy resin) so i can use weld on to make it stay in place since using silicone would be pointless.

I did find the Touch 'N' Foam for a very good price online, got 12 on order, hopefully that will be enough, if not I guess I can always use the great Stuff at Lowes or HD, plus I think I have a can or 2 laying around already :)

I also read in Kannin's thread of people using a dremel with various bits to carve and resurface the foam prior to laying down the substrate. I thought this was a good idea as well, and will most likly be giving it a try once I start construction!

Look for the build thread soon!

Thanks again for the inspiration!

Scott
 
atlantiscoral, don't ask me why it took so much, I don't know, maybe I overdid it.. but I did 7' x 30"and around the overflows plus the freestanding pieces too!

I think all the other epoxy methods work too, I was contemplating them aswell, it was just too easy for me to get the Epoxy I used, delivered to my door....

Dremel is ok, regular knife works too. But there is a point sometime after it skins over and before it hardens where you can manipulate it with your fingers (WEAR GLOVES!!!). You can push the air out, twist it and turn it, thumb it and squish it, squeeze it and poke it, whatever shape you want. Works great, you just have to time it and be prepared to change gloves if you catch it before it's ready....you'll get the hang of it, try it on a small section first.

I just extended my back wall up to prevent any jumpers from escaping and I did the same thing and added some shells and dead coral for looks, since I couldn't coat it with epoxy and sand. I'll post some pictures asap.
 
<a href=showthread.php?s=&postid=14188297#post14188297 target=_blank>Originally posted</a> by Speckled Grouper
atlantiscoral, don't ask me why it took so much, I don't know, maybe I overdid it.. but I did 7' x 30"and around the overflows plus the freestanding pieces too!
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I dont think you could use "too much" per say :) I am just amazed that Kannin used so little! I guess it really comes down to preference... I am soon to find out!


I just extended my back wall up to prevent any jumpers from escaping and I did the same thing and added some shells and dead coral for looks, since I couldn't coat it with epoxy and sand. I'll post some pictures asap.
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Awesome. Has that been an issue? Thankfully I wont need to worry about that since the tank is eurobraced.

I am 'cant waiting for new pics! :)

Scott
 
<a href=showthread.php?s=&postid=14142753#post14142753 target=_blank>Originally posted</a> by Speckled Grouper
Here is a picture from tonight
FTS4.jpg
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Bravissimo. :rollface:
 
Awesome, good info thanks. I just got the rest of my stuff for it today. Should i document and post? Not sure since so many people have already. We will see...
 
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