gguertin,
Hey man. A week waiting today would be far better than heart ache down the road. I have my materials coming in right now and spent extra money and time researching and waiting for what I believe to be safe to come in. Here are some links to the products I have found. All of these are supposed to be safe for aquarium use.
This is the epoxy I bought I called these people and told them what I wanted to do with their product. They were very friendly, knowledgeable and helpful. They assured me their product was indeed reef safe.
This is the foam I am using
I also found this epoxy on eBay.
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=280208100731&ssPageName=ADME:X:RTQ:US:1123
I contacted company last week and asked them the following questions. It took them more than a week to answer me and then only after a second email so in the mean time I ordered the above epoxy instead.
1) Would it be suitable for this?
2) Are there any detrimental effects from UV, specifically metal halide lamps? 3) Does it contain styrene? 4) Any chance of leaching? Thanks in advance for taking the time to answer my questions. If this product is suitable in all aspects I will be more than happy to post your information
Their answers follow.
Question #1 Yes; MAX ACR would be suitable for this application.
#2 pigmented epoxy resin should have no concern with UV. You might to take a look at our MAXBOND Thixotropic also. Here is the eBay item number; 280177201457
#3 No, this product does not contain styrene.
#4 There would be a chance of leaching if the product is not properly mixed. You must have accuracy.
I realize many people have used products that are not known to be safe for this application and not had a problem. Perhaps I worry too much but the worst thing I can think of is to get every thing built set up and running and then start having problems. Whether the problem is actually associated with the reef building project or not if I can't rule it out then it would be suspect.
The purpose of the epoxy is two fold from my understanding. First, it protects the foam for UV. UV will affect the foam over time. Secondly, it provides a tacky surface to hold the crushed coral and sand which is what gives it a natural appearance. Over the next few weeks I will be building out my tank and will post a build thread.