How to make a spray bar to replace the AGA overflow nozzle

[electric130]

okay, here it goes. my first "big" tank is my current 90 gallon setup. it's a predrilled with overflow AGA. i bought the plumbing kit (big waste of money) for it too. i quickly learned that one return with 1000gph coming out of it causes a horrible flow pattern. i bought a Y-adapter to try to fix the problem. while this helped, it also was a waste of money. so one day while shopping at Lowes, i saw some things and got the idea to try to build a spray bar. i didn't want to use white PVC because it would stand out too much. then i saw "Silflex." it was cheap, and black. perfect. so i got a 5 foot piece of silflex (looks like black PVC, not as rigid) for $2, a plug for $.30 and a threaded nipple for $.50 i drilled about 25 holes in it. so for less than $3.00, here's how i made my spray bar.

the holes in the pipe are hard to see in the pictures. i started out with about 13-14 holes and then went crazy (after it was installed) and drilled about 12 more. the more holes, the lower the velocity of the water coming out. i used a 7/32" drill bit, but you could use a larger/smaller bit with less/more holes to make the spray bar do exactly what you want it to.

here's the y-adapter that i wasted money on before doing the spray bar mod:

here's the plugged end of the pipe:

here's the threaded end of the pipe, i put a couple wraps of teflon tape on the threads before installing:

here's the whole pipe:

here's the pipe installed from the top:

and here's an in-tank shot:

the over all water movement in the tank is much better and my corals showed signs of being happier within days of the mod. you can't see it in the pics, but the plug and the threaded adapter have a barbed nipple that goes in the pipe. i heated the pipe to let the fittings go in easier. by making the plastic softer, the barbs bit into the plastic more and once they're in there, they're not coming out. as you can see, i didn't even use any kind of clamps, they're simply not needed IMO/IME. hope this helps.

anyone is free to ask me questions if you have them.

 

[H20ENG]

Nicely done, and thanks for sharing!

 

[Matt897]

Very cool mod i have a 55 with the same overflow thing that i got from all-glass... its alright but i've thinking about building an external return system that will have two diagnal shaped pipes running up the back, coming over the top into the tank giving off 4 returns total.... what do you think? or maybe i'll go with your idea for the spray bar return system. what are your thoughts electric 130? I thought the 90 came with two overflows in the corner (if its from all-glass) if it is from them, its way undersized... New system looks great, best of luck!!!! Ohhh one question electric, at the top of your overflow wall where the water comes from the bottom intake and merges with the top overflow, does it get all nastey and slimy? I have that cheap plastic thing that slips into the sandwhich shape opening and its all slicked up,you think i should keep it in?

Thanks

 

[electric130]

Very cool mod i have a 55 with the same overflow thing that i got from all-glass... its alright but i've thinking about building an external return system that will have two diagnal shaped pipes running up the back, coming over the top into the tank giving off 4 returns total.... what do you think?

not sure exactly what you mean.

or maybe i'll go with your idea for the spray bar return system. what are your thoughts electric 130? I thought the 90 came with two overflows in the corner (if its from all-glass) if it is from them, its way undersized... New system looks great, best of luck!!!!

it's the standard 90 gallon AGA. it only has one overflow. i wish it had two. i had to drill out the tops of the overflow slots so that the overflow actually skimmed the surface. before this, the water level was above the tops of the slots and i got no surface skimming. see pics. first is with pump on, second is with pump off:

Ohhh one question electric, at the top of your overflow wall where the water comes from the bottom intake and merges with the top overflow, does it get all nastey and slimy? I have that cheap plastic thing that slips into the sandwhich shape opening and its all slicked up,you think i should keep it in?

i took mine out after about two months. don't know what it's for, but my water level and flow rate is better without it. also, after drilling the holes in the overflow, flow is obviously better too.

 

[Matt897]

ooooo cool, i just saw mine yesterday and it looks terrible... i'll take it out tommorow. nevermind on the return system, i'll maybe make a picture tommorow to show you and i'll post it on this thread. maybe i'll drill holes in the grates also... maybe help some flow out... Hey do you think that my unmodified overflow can take a mag 9.5? i know it matters o the sump, but you think the standpipe going down can handle the flow? tell me your thoughts

 

[myakkareef]

Good Idea on the spray bar, I have a 125 AGA been working on something similiar but i like your ideas using the silflex. Also on my tank I cut small curved shaped covers out of 1/8 acrylic and they sit on the tank rim to stop all that Salt Creep above the overflows. I will take Pic tonight to show you what i mean. Really help abunch and does not inerfere with any plumbing. Thanks for your ideas.

 

[seirk]

Matt897: I had a 75 AGA that used a Mag9.5 in the sump below the tank. The tanks overflow could only handle the flow once I modified the slits similar to electric...

Otherwise it slowly creeps up and over the overflow :eek1: :eek1:

 

[electric130]

my pump (LG 3-mdqx-sc) did the same thing until i modded the overflow. the downdraft pipe could handle the flow, it was just those stupid little slots that were the limiting factor.

BTW, just replace the LG with a CSL velocity T3, what they say about them being so quiet you have to touch them to see if they are running is true. i was and still am ABSOLUTELY AMAZED at how quiet, no, silent they are. i was giggling like a little school girl. now if i can just come up with a way to quiet my canopy fans.

 

[Matt897]

lol very badass... i want one!!! but i need money of coarse and i spent it on my tank obssesions... but when i get the right amount of cash i'll upgrade my tanks return system and will get that nice new mag pump... but i have another question... is that quite pump that you were saying only extrenal or internal or both? it sounds cool but is it expensive? Anyway thanks for all this info on this type of overflow... i've been looking for people with a similar system for a long time... YAY!

Thanks again, i'll try to make a drawing of that return system that i spoke about earlier in MS paint :lol:

 

[electric130]

the T3's and T4's are about $160 online. the T3 pumps 800 @ 3ft and the T4 is 1225 @ 3ft. i have the T3. i got it used from another ReefCentral member. keep your eyes open. people sell them every now and then. all of the CSL Velocity T series pumps are external only. if i can help it, i'll never use another submersible pump again. i just like the externals better.

 

[Matt897]

here we go

here we go

here i made a quick drawing of the return system it has a y in the back and each side goes over the top edge of the tank into the water... each branch has 4 return spouts. Any comments or questions? think i should have more openings if i'm using a mag 9.5? let me know!!!!

 

[Matt897]

nevermind, i can't upload the damn thing, its to big... o well i give up!:mad2:

 

[electric130]

i think i know what you're saying. as far as the returns go, the more you have, the lower the velocity of the water coming out of each return. i have considered adding a closed loop and putting a couple spray bars (they're so cheap to make and give awesome flow) behind the rockwork.

 

[Matt897]

hmm

hmm

sounds cool i may just do some spray bars i suppose. I was thinking if i did do this new external return system that doesn't use the stock return given, i'll either just close up the current return or take off the nozzle, cut it down, and use it as a second overflow standpipe to help water get to the sump if the flow isn't enough... i like that idea alot, because the return pipe can be used as a second overflow to a second drip plate in the sump or what ever you want to do! maybe you can consider that in the future if you get a bigger badder pump instead of using the current standpipe to full capacity or close to it... Best of luck

 

[electric130]

the only problem i can see with using the return as a downdraft is that both pipes would have to be the exact same height. i think it might be a headache to get things adjusted just right.

 

[Matt897]

well actually no, the other pipe would be as closly cut as possible just to be able to take on any extra water the main pipe can't take at once, its an overflows overflow sorta speak. the purpose is to enable you to have a larger pumping system if wanted...

 

[electric130]

if it's just left open, and water goes into it, you're gonna get that horrible sucking sound. to avoid that, you'd have to make it a durso. i think it would be hard to get two durso adjusted right in the same overflow. unless you ran the two pipes up, elbowed them into a large T (like 1.5 or 2") and then made the durso ontop of that. understand?

 

[ri]

electric130,

Great job!

I've been wondering what to do with the returns on my 180. Once it warms up a bit outside (or shall I say, If it ever warms up) I know the first project to work on!

ri

 

[Matt897]

hmmm thats probebly a good factor to put in the batch... noise.... well i doubt people would be using a 4000 gph pump but if they are, the second stand pipe could have a float on it similar to the main pipe... i think if your running a system that complicated and powerful i'd expect some noise anyway but thats just my opinion anyway... I think i may do your idea with that new return system spray bar, it looks absolutly wonderful and is a genious move! Hows it working now? do you get a strong current on the last couple of openings? What kind of pump are you using?


Thanks:eek1:

 

[electric130]

flow seems pretty even out of all holes. don't know how or why, but it is. i just switched to the CSL Velocity T3 today. so far, i love it. you can't hear it at all, and that's not an exageration. the spray bar mod was done a month ago. i wish i would have thought of it a long time ago.