Sharp's 450g Plywood Build (finally getting closer)

masharp1126

New member
Well, thought I'd finally get this thing rolling. Let me warn you right up front that I'm a huge procrastinator. But, with that being said, this project has been in the works for over 12 months so far, time to get it done. My goal is to have the tank completed, water in, plumbing & lighting done, and fish room complete by the end of November.

First, I'd like to mention DSANDFORT and Sean : EbN, whose build threads were incredible and gave me so much of the information that I needed to do this. I've read so many plywood build threads on the past 1 1/2 years, but they still fascinate me.

Anyway, let's get started.

We moved into our home in November of 2006. The home had a 3-car garage, but somewhat different than most. Instead of 3 spaces side-by-side, there were 2 side-by-side, and one of the spaces was 2 deep. L-shaped. The 2-deep side also shared interior walls with my den, as well as with the laundry room. Making it an ideal space for a new fish room with an in-wall tank. In some of the pictures, to follow, you'll see that I walled in the space, installed (3) 20amp circuits, cut the hole for the tank, started the stand, and installed a tile floor. Still a lot to finish up, but it's getting there.

Before we start with pictures, here's some anticipated specs on the tank and fishroom.

Display - 450 gallons
- 72 x 48 x 30
- Coast-to-Coast External Overflow
- Made by Me (Plywood)
- 70% SPS, 20% LPS, 10% Softies

Fish Room
- 15 ft x 10 ft fish room
- One section of a 3-car garage walled in and converted to a fish room
- 3 (20amp) circuits run to the room for all equipment
- Floor tiled and moisture proofed about 6” up the wall
- Utility cabinet and sink will be added. One wall backs up to laundry room and will tap into the water source and drain. RO unit will hang near the sink and tap into the laundry water source as well. Still thinking on how to best collect and use the waste water.
- Cabinets built next to tank stand to house RO water storage tank, salt water storage tank, frag tank, and quarantine tank. Cabinets will also hold controllers, reactors, and supplies.

Refugium
- 78 Gallons (capacity of 103g)
- 42” x 31” x 18”
- Plywood construction, epoxy sealed.
- This will be located under the tank beside the sump. Overflow from the tank will be split between the
refugium and the sump. Refugium will overflow into sump. DSB and Chaeto in the refugium.
- 2 x 39W T-5 bulbs

Sump
- 52 Gallons (capacity of 103g). Total emergency capacity of almost 78 gallons, which should be
enough in the event of a power failure.
- Plywood construction, sealed with epoxy
- Might or might not contain the Protein Skimmer, depends on which skimmer is chosen.

Frag Tank
- 40 Gallon Breeder tank
- 36” x 18” x 16”
- 2 x 175 watt MH w/ XM10Ks (using these because I currently have them from an older tank)

Salt Water Tank
- 40 Gallon Breeder tank
- Used to create new saltwater for water changes. Was thinking of doing 40g water changes weekly, but with a total system capacity of about 650 gallons, might need to rethink it. If I do feel I need to do larger changes, I might add a 2nd 40g breeder and bump my capacity to 80 gallons.

RO Water Tank
- 40 Gallon Breeder tank
- Used for auto top off, as well as to replenish the Salt Water Tank after water changes.

Quarantine Tank
- 40 Gallon Breeder tank
- Stand-alone system with some type of bio-wheel for filtration.

Skimmer
- Undecided. Possibilities include Trigger Systems TS1000, PM XL-2, ASM G5 or G6,
Octopus FDNW-400, or maybe even DIY (not sure where I’ll find the time)

Ca Control
- Balling method to begin with. Adding Kalk and CA reactors in later stages

Display Return Pump
- Reeflo Dart throught 2 1” Seaswirls

Frag Tank Return Pump
- Fed off of return pump

Media Reactors
â€"œ Phoshate Removers, Carbon, etc., fed off of return pump to a manifold

Circulation
â€"œ Dart return pump through (2) 1” Sea Swirls, Dart closed loop, and 2 Tunze 6200’s to begin
with. Roughly 15,000 gph for a turnover rate of 34X.

Controllers
â€"œ Milwaukee PH controller for CA reactor. Ranco dual stage reactor for heaters and chiller (chiller to
be added later). Eventually add an AC Jr for lighting, pumps, and PH monitoring.

Temperature/Humidity Control
â€"œ Heater in the sump will provide heat for the tank, when necessary. The temperature in the fishroom will be maintained by a window A/C unit installed in the wall. Exhaust fan installed and controlled by a de-humidistat. A stand-alone de-humidifier in the fishroom (not sure of the size unit yet).
 
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Here's some pics of the fishroom so far. Keep forgetting to pull out the camera as I go and snap shots, but you should get the idea.

Wall is already framed and rocked. Door still needs to be installed and A/C unit.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures061.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures061.jpg" border="0" alt="Garage into Fishroom"></a>

Another that shows the door that goes into the house. You can kind of see were I pulled the sheet rock off of the wall and left the part to indicate where the tank will be.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures062.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures062.jpg" border="0" alt="Garage into Fishroom 2"></a>

Here's another that better show from inside the fishroom. Would have liked to have gone about 8ft long with the tank, but only had about 6ft to work with. By centering the 6ft on the den wall it left me just enought clearance to get into the house by the door you see in this picture. You can see 1 of the circuits that I ran below the tank.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures063.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures063.jpg" border="0" alt="Fishroom 1"></a>
 
Here's the rest of the tank wall. 2 other circuits are located to the left of the tank area. This area will house the cabinets that will hold the frag tank, quarantine tank, RO tank, water changing tank, and overall work area. Kicking myself for not adding an outlet above the tank for the lights. Must have had a brain freeze that day. Might not be too late, I'll have to check. Just tear out some sheetrock, and do it over. Might be worth it in the long run.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures064.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures064.jpg" border="0" alt="Fish Room 2"></a>

Here's the view from inside the den. The tank will be centered on the wall where the plant is. That's my chair, btw. Will have the perfect spot for viewing the tank and the LCD.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures066.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures066.jpg" border="0" alt="Tank Wall"></a>
 
Framed out the opening. Wasn't sure if this was a load bearing wall, but went ahead and supported it while I installed a header. Don't freak out too much about the electrical here, we did clean it up a lot before sheetrocking. I ddn't have enough wire to keep it clean in the beginning, but after a trip to the hardware store, we got it cleaned up.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures123.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures123.jpg" border="0" alt="Photobucket"></a>

I'll have to get some better shots of the fishroom, now that it's further along. Took several at the beginning, then slacked off. The stand is only partially done, don't worry, there will be plentry more vertical supports before I'm done. Wall is sheetrocked, tile is installed everywhere except where I'm going to build the cabinets to the left of the tank. My wife even installed a tropical mural on the wall opposite the tank. Looks great, I'll try to get a pic. It takes up most of the wall.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=Picture006.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/Picture006.jpg" border="0" alt="TankRoom1-6/16/08"></a>
 
And here's some of the tank being built. Sorry I didn't get many pictures during the cut and assemble phase. This is the front of the tank and along the top you can just make out the angle iron used to strenthen that section. Got the idea from DSANDFORT on his build and thought I'd give it a try. Should eliminate any deflection, but will be ready with another type of brace if needed after it's filled.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures289.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures289.jpg" border="0" alt="Photobucket"></a>

Here's the coast-to-coast overflow being added.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures292.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures292.jpg" border="0" alt="Photobucket"></a>
 
Better shot of the angle iron. Front of the iron already enclosed in the wood overlap.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=2007Pictures294.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/2007Pictures294.jpg" border="0" alt="Photobucket"></a>

Now, no iron visible or exposed.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=450gPlywoodBuild004.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/450gPlywoodBuild004.jpg" border="0" alt="Photobucket"></a>

Sanding away. You can see that I've now added most of the reinforcement on all corners with overlaps. This shot is of the back and bottom. Even added some decorative sides to the overflow.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=Picture004.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/Picture004.jpg" border="0" alt="Tank2-6/16/08"></a>
 
Last one for now. Shows one end and the trim piece covering the overflow is shown better.
<a href="http://s91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/?action=view&current=Picture001.jpg" target="_blank"><img src="http://i91.photobucket.com/albums/k286/masharp1126/Plywood%20Tank/Picture001.jpg" border="0" alt="Tank1-6/16/08"></a>
 
Looking good man! Having a woody myself I always like to follow these threads. Keep the pics coming!
 
CyclistMT, thanks for the comments. Finally have a weekend coming up with no honeydo projects, so should be able to get lots of epoxy applied. Hopefully get some work done on the fishroom too while the epoxy is setting up. Still need to grout my tile and finish up the walls.

Will be sure to take and post pics as I go.
 
Welcome Ratpack.

For the lighting experts out there, take a look at these. I've got 3 lumenarcs that I plan to use on this tank, but happened to pick up some of these at work the other day. They were about to throw them out, as the ballast were out on them. Thought I might hook one up sometime after the tanks done and see how they compare. The bulb does mount vertically, so not sure how that would affect the light output. These are used in warehouses and normally house MH or sodium bulbs.

Picture007.jpg


Picture009.jpg
 
<a href=showthread.php?s=&postid=13014583#post13014583 target=_blank>Originally posted</a> by masharp1126
Welcome Ratpack.

For the lighting experts out there, take a look at these. I've got 3 lumenarcs that I plan to use on this tank, but happened to pick up some of these at work the other day. They were about to throw them out, as the ballast were out on them. Thought I might hook one up sometime after the tanks done and see how they compare. The bulb does mount vertically, so not sure how that would affect the light output. These are used in warehouses and normally house MH or sodium bulbs.

Picture007.jpg


Picture009.jpg


Polish them up to a nice shine and who knows...you might have people swaping out their lumenarcs :)
 
AgentSPS, wouldn't that be funny, and here they've been throwing them in the salvage dumpster.

One person's trash, another person's treasure. I'll definately have to start collecting them, at least for now.

Anyone out there that has the ability and desire to test one of these, I'd be happy to send them one. Would even be willing to help with shipping cost for someone, as long as they have the equipment (meters, etc) to set it up and test it. Would be nice to know sooner rather than later if they're worth saving from the scrap yard.
 
Stopped by Lowes last night after work and picked up some stuff for this weekend. Between coats of epoxy, I'm going to try and get my walls finished in the fishroom. Have one section of drywall to replace and then start painting. Already have one coat on most of the room.

The paint I'm using is Zinsser Perma-White Mold/Mildew Proof with a yellow tint to it. The guy at Lowes recommended it as the best moisture proof one that they carried, so hope it works out okay. I know it's hit or miss with those guys, but I know very little about paint.

Also going to install some crown molding and probably some corner mold as well. I know it sounds a little excessive for just a fishroom, but it's actually to hide some of my flaws. My tape and bedding isn't the best in the world and my corners (wall-to-wall, wall-to-ceiling) don't look that good. So I'm thinking, why not cover them up with molding. Molding I've done lots of. At the rooms small enough that it won't cost that much.

Anyway, that's the game plan for this weekend (might even cut the rest of the 2x6 legs for the stand). Will definately take some pics along the way and post.
 
very nice work. is this your first plywood tank build? kinda interested in doing one but wasn't sure about the ease of constructing one and the price of what it would cost to build one. would it be possible to get a build sheet with prices on it?
 
am3gross - yeah, first plywood build, thanks for the comments. I've tried to keep a running total and I'll try to post something later today, if the job allows time.
 
Well, here's a pretty close estimate of the costs. The only thing missing from it is the cost of silicone. Haven't bought it yet, so not sure how much it will be or how many tubes I'll need.

Does anyone have a link for the particular tubes of silicone that I need?

Building Costs
Trim Wood $160.00
Plywood $140.00
Epoxy $280.00
Fiberglass $95.00
Glue $10.00
Screws $18.00
Paint $90.00
Angle Iron $24.00
Glass $300.00
Silicone
Misc (brushes, rollers, etc) $30.00
Total $1,147.00


Have some plywood and epoxy left that will be used for the sump and refugium builds.
 
Got quite a bit done this weekend. Shocking! :smokin:

Got my tile grouted, A/C unit installed above the door, finished epoxying one end of the tank and flipped it to the back, and got all the legs cut for my stand. Here's some pics.

View from the garage looking towards fishroom. A/C unit installed above the entry door. Still need to add some insulation to either side.
Picture015.jpg


From inside fishroom.
Picture013.jpg


Mural that my wife bought and we put in. Wanted it to give the effect that your looking out a window at the beach.
Picture014.jpg
 
Just noticed that my thread title has changed.

Can we at least make it "Sharp's 450g Plywood Build", so that people know it's a plywood tank?
 
If you post in the Feeback & Questions forum asking them to change the title to "Sharp's 450g Plywood Build" (if thats what you want it as) then they will get onto it when they can. ;)
 
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