I've never read so much about LEDs in one sitting in my life.
I have to say this thread has been very interesting.
#1) spray foam is perfectly fine in the tank once it cures, and there was even an interesting article about it in Reefkeeping Online about two years ago. There are tanks running right now with the black foam (sidewinder's
375g reef) that look great.
#2) GE Silicone II without mold inhibitors is perfectly fine. They have two versions of "II", so just read the tube to make sure you have the right one. Let it cure 24 hours before adding water.
The LED arrays you made look fantastic. Sorry some of them are shutting down on you, as that was a lot of work. This was a very interesting thread to read, and see what occured over the past 60 days.
Eggcrate is available at Home Depot in the lighting department, but your LFS could probably give you a small piece if you still needed it.
I don't even want to know how you managed to pee in a teaspoon. Twice! Talk about control... :lol:
Keep up the good work. It is definitely fascinating. When I was at MACNA last fall, there was a small 5g tank with a 6 LED fixture. It had tiny LED ballasts. Here's a few pictures. I guess the aluminum heatsink keep the bulbs cool, btw.
Based on Dana Riddle's talk about running moonlight LEDs 24/7 and actually bleaching corals where the light beam hits it precisely, I was thinking you could plug your power supply into a timer. When the timer is on, the LEDs will all run. When the white LEDs cut off, the blues are still on for a couple of hours - great idea, btw. Then the timer turns off and the blue LEDs turn off as well, giving the corals some rest in total darkness.
I hope your project continues to work out as planned. :thumbsup: