One more step in the process was started today. I worked on fabricating the structure that will support the lights above the tank. I used square, 1" extruded aluminum tubes from EZ Tube, which many here on RC have used as well. I have to say the components make for a really professional looking finished product.
The basic dimensions are 51" long x 14" wide x 8" high. The dimensions were pretty much governed by the 48" tubing I ordered. This will support two Ecoxotic 100w Cannons and two 60" Hamilton Aruba Son fixtures. I'm waiting on delivery of the T5 fixtures. The Cannons will mount to 1/4" aluminum plate that insets on the top of the structure. I have a pretty good idea on how I'll mount the T5s as well. The entire assembly will be suspended from the ceiling via a pulley system so I can adjust the height above the tank as needed.
There are some things to consider when using EZ Tubes. To begin with, I used a fine tooth wood cutting blade rather than a composite metal cutting blade. The wall thickness of the tubes is thin. I achieved a much cleaner cut with the wood blade. Second, I made a small jig for the chop saw. Jigs are a great way to prevent blowout when cutting wood and they work well for metal cutting too. A cleaner cut is achieved with the jig. It also provides great reference for measuring cuts. Just be sure to clamp it to the fence of the chop saw.
The EZ Tubes and connectors need to be driven together with a hammer. I found a 3lb. lump hammer was perfect for the job. The connectors are really durable and can take the hits without deforming or marring. When needed I used a birch block over and under the pieces being forced together.
A note on the connections. In most cases, these connecting points are impossible to pull apart. If you make an error, you'll need to drive the connector off of the tubing. Not an easy task. I did make a change and had to do this. However, there were three short pieces on the 8" vertical that were easily pulled apart from the connectors. Obviously holding electrical equipment above the tank, I am concerned about this, so I drilled and screwed the verticals an inch in from the connecting points. Not sure why this occurred, but I guess the tolerances may be an issue. So if you use this system, check the security of the fit. I don't mind having the screws. I placed them on the inside of the legs so they're not even noticeable. All this said, the entire assembly doesn't need the screws. I just feel better that the vertical parts won't pull out having the whole thing fall into the tank.
Here's some pics of the process and the final product.
I expect a delivery from US Plastics for the plumbing fittings early next week and hopefully I'll have the Hamilton fixtures by then too. I'd like to get the light support mounted so I don't have to keep moving the tank around by myself LOL