The sickness continues... FroMan's 180 gal Glass Box Build

FroMan

Insane in the Brain
This thread is to document my progress on building a 180 gallon ecosystem. I've spent the last 4 years learning a ton on my 55 gallon tank w/ 40 gal sump. The engineer and scientist in me have been intrigued, engaged, and mystified by the biological organisms that live in the tank. For as much as I’ve learned about chemistry, physics, and biology I’m still amazed at how life forms function. If you *really* sit down that think about it… it is absolutely amazing what we are able to accomplish in our tanks. Sometimes I think we on RC are to “equipment”, “supplement”, or ”technology” centric that we sometimes forget what is really going on in our glass boxes……

I'm enthralled at the ecosystem that is alive in my 55. I hope to build a more captivating 180 gallon tank.

I do want to thank some individuals that have been a major inspiration as I've lurked through their threads on RC. Melev, mpoletti, Cato, SunnyX, Weatherson and countless others. The more information we share with each other, the more successful we all can be. Thanks for sharing and documenting your successes and failures! I also wanted to thank the local CTARS members for their ideas and willingness to show and discuss their tanks (shark bait100, fitch4, hans1976, cato)

This was supposed to be a "spring time project". Unfortunately, completing my master's degree took a bit more time than I had anticipated along with those "fun life experiences" that bite you experience from time to time.

This story starts in late summer of 2008 at MACNA in Atlanta with the purchase of a Deltec APF600. I don’t remember the shop that I bought it from, but it was a very good price for the skimmer compared to retail pricing. I also enjoyed talking with the Deltec personnel. They were very helpful and knowledgeable about many different reef related topics.

Fast forward to the fall of 2008 the search for a tank begins! The original plan set out to buy an Oceanic w/ starphire glass. During that search I came across an awesome deal that Bob @ Cultured Aquatic Life here in CT had on an AGA 180 w/ dual mega overflows. Needless to say I couldn’t pass up the deal. The savings gave me fore flexibility with lighting and a controller :) I drove down to pick it up. It *just* squeaked into the back of my Subaru with the passenger seat as far forward as it could go.

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So progress on this build came to a screeching halt in late January as I was coordinating a group buy…..

There the tank sat in my garage for the last 6 months collecting saw dust from house projects, pollen from everything that bloomed this spring (and drove my sinus’ nuts), and to occasional spider web from time to time.

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Even though the spring was, well, insane, I was able to pick up the rest of the equipment on my list…….
 
Now that the semester is over and house projects are being reduced (for now). I've taken the opportunity to get things rolling again.

Equipment list for the tank so far:
Skimmer - Deltec APF60
Return pump: Iwaki MD40
Power heads: a pair of VorTech MP40 w/ battery back up
Lighting: Current USA Nova Extreme Pro T5
Controller: AquaController 3 w/ standard pH and temperature probes, 2X DC 8, Dimmable Lunar Simulator w/ 5 LEDs
Chiller: Pacific Coast Imports ½ hp (used from a local CTARS member)

I had also won a Coralife calcium reactor basic setup at the annual CTARS conference, but it is on the back burner until the tank is alive and kicking.

During late January into early February my dad and I installed a laundry pump down in the basement to take some load off the washing machine. (Thanks Dad!) We also added a sink at the same time so I would have a drain down there and a slop sink in the basement.

laundry_pump.jpg


Recently my wife and I started to paint the basement walls to make it look like less of a dungeon. Not that I'm going to be spending as many hours down there as I do in my office, but I wanted to make it a bit brighter. The paint made a HUGE difference in the brightness of the basement even with the 75 W incandescent bulbs that are down there (picture below is with a flash).

New lights will be installed when I start to work on the electrical. Home-do-pot has some 2 bulb T5 shop lights for ~$30 each. These seem to be pretty reasonable price wise so I will be picking up several of them to brighten the place up once we are done with the painting.

painted_basement.jpg
 
Now the fun stuff ..... :rollface:

I took some time last week after work to get the stand's frame design solidified. This is based off of mpoletti ‘s design. (Thanks for the extra pictures Mark!)
The basics of the frame:
Top and bottom frames are 2X6's for symmetry
Legs are 2x4's
Top and bottom decks will be 3/4" ply

Yes it is WAY over designed. I’m an engineer!

This week (time permitting) I'll start to model the facing and doors.

Other fun stuff….. I took a trip to the Connecticut Wood Groups Hard Wood Outlet. WOW!!! If you live in CT or Mass, defiantly worth the short drive to Enfield if you are looking for any type of hardwood for a project. My wife had to scrape my jaw off the floor when I walked into this place. Absolutely gorgeous pieces of unfinished hardwoods. Picture a 2” thick, ~10 in wide, 12 foot long pice of mahogany. Yeah, mahogany….. I don’t think I’ve seen a warehouse like this in my short duration on the planet……

http://www.cwghardwoodoutlet.com/

Below are some CAD models of the designs I put together for the stand’s frame. At the moment, I'm leaning towards using a cherry ply for the stand's facing and door inserts. More to come in the next couple of weeks as I start to order materials for the frame

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Its has been a while since I've updated this, so here we go....

Ubiquitous pile o' raw materials
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Cutting and stacking....
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Starting to build the 180's frame.
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A little further along on the 180's frame.
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Construction of the sump's frame (in the basement)
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Completed frame for the sump.
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Routing the details into the cherry door frames.
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Completed frame and facing for the 180 - unstained cherry ply on the surface.
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Stained doors
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Stained "floating panels"
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Stained 180 stand
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Completed doors with spar urethane applied to doors.
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Spar urethane applied to 180 frame.
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Completed frame in place in our family room. I'll be putting the doors on once the stand is in place and the plumbing is complete.

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Next steps:

- moving the tank onto the stand
- putting epoxy down on the basement floor
- Installing (1) or (2) 20A circuits in the breaker box and running electrical lines to the corner of the basement were the sump and majority of the equipment will reside.
- Setting up the 75 gallon sump
- Starting the plumbing

I'm shooting for water by the end of October, but who knows with work :confused:
 
Very nice build...

are the foating panels for the doors the same wood and thickness as the frame they go behind?
 
Just a quick update from this weekend. With the help of two friends and my wife, the tank was moved onto its stand this afternoon. :spin2:

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I decided that I was going to bring the light up out of the basement. I had to move it anyway as I was starting to shuffle things around in preparation for the epoxy anyway.

The light was put up with stock bulbs from current. Man this sucker (Current Nova Extreme Pro T-5 ) is bright. It doesn't even compare to the coralife PC that I have over my 55. I just wish I could figure out what I did with the legs to lift it up off the tank. They are around here somewhere! :rolleye1:

For the engineers.... Pretty much dead nuts. 3' long Stanley level. I'm guessing that I'm somewhere between 1/16" and 1/32" off left to right. Front to back and from the corners to the center it is right on.
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Basement floor was epoxied over the weekend. It is amazing the difference that it makes to the look of the room. It is no longer the dungon like room that it once was. Pictures to come soon.
 
So it has been a while since I've posted an update to the thread. A lot has happened over the last few months that kept me from making the progress that I would have liked on the tank, but you have to roll with the punches.

This is a picture of the basement with the epoxy floor completed and the main sump stand in place. The floor came out nice, but I did notice that in different areas of the basement the epoxy was absorbed by the concrete differently. Overall I am happy with it. It is a basement after all.



Next up was an adventure in plumbing. I probably spent a good 8-10 hours working out a plan to keep things as symmetrical as possible to ensure that each side would flow equally.

My dad gave me a hand when my parents were vising over Thanksgiving. It was helpful to have another set of hands to hold things together while the glue was setting on the pipes and fittings. I finished up the plumbing for the basement sump over the next week and a half or so.

Since it was holiday time, I decided let things sit until January as I didn't have the time I wanted to double check things and I didn't want to have any leaks while I was visiting family for the holidays.

About the second week of January I started filling the sump with water. I transfered water from my storage containers into the sump saturday morning and started making more RO. I came back down into the basement to find puddles on the floor. :mad: The used tank I had acquired for the sump had sprung a leak and I had no idea from where.

I considering draining it and reapplying silicone to the entire tank. I went back and forth on this for about and hour and decided to check the pricing on a new 75 g for the sump. One of our local fish stores, Realm of Pets, had a very good price on the tank, so I had them order me a new tank for the sump. The down side was that I lost about a week and a half. :sad2:

Fast forward to the next closest Saturday, I pick up the tank, drilled the side for the bulkhead fitting, sealed everything back up, and started where I left off..... filling water

Let me just say that filling a tank takes a LONG time. Especially when you don't have a float valve set up on the water storage system and you are only letting the water run while you are home. It took about a week, but I got everything filled up to start the "fresh water" check.

Picture of the tank full of RO/DI for a water check
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Plumbing under the tank:
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Sump and return plumbing:
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Manifold and DC8 for the AC3. This is probably not going to be the final resting place for the DC8, but I put it on the board as a starting point.
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After I was happy that there were no leaks, in went the sand.

Is there something in there?
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Ahhh... some clarity on the situation.
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After all the dust settled out, I let things run for a good week prior to adding salt. One our local club members had mentioned that he had cycled his tanks with mollies, so I figured that I would give it a try.

By the end of January the tank had salt in it and I began the cycling process. I had bought Prodibio START UP on the recommendation of a fellow reefer, so it went in after the salinity was in check and stable.

Now for the ubiquitous light picture..... I'm currently running a 72" Current USA Nova Extreme Pro T5HO with the stock bulbs.

Daylight + Actinic lighting
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Actinic Only
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More to come..... :fish2:
 
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