My DIY internal PVC overflow w/pics & vids - comments/suggestions welcome!

[llebcire]

So I'm building a 72g bowfront and decided to try my hand at my own internal overflow. I had a 75g RR Oceanic before, and the factory overflows seem to take too much real estate.

I decided to go with PVC, considered building internal overflow box with glass, and I could always do something different later (unlike factory overflows). This design won't take any landscape on the floor of the tank nor should it inhibit too much light.

Overflow needs to be reliable and quiet as this tank is going into the living room. All will be painted black with Krylon Fusion when finished.

Found an old (archived) thread by ibmgeek (http://archive.reefcentral.com/forums/showthread.php?threadid=969798) using this overflow:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/246152663.jpg

So I set out to attempt something similar:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7105.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7106.jpg

I also decided to set up a test rig for experimenting, for clarification the "T" will be behind the tank and in this case is where the bulkhead will eventually go as the tank will be drilled on the back wall as the bottom is tempered:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7195.jpg

Old bucket that I'll drill:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7193.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7194.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7197.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7198.jpg

[llebcire]

Setting up in a cooler using pop cans for a shelf and a Rio 2500 for a short return.

One concern is that this will be more flow than in the tank, I think I will only go so far then wait to fine tune in the tank while leak testing.

Cooler

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7199.jpg

First vid showing intitial setup

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7230.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7230.flv)

More
http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7231.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7231.flv)

3/16" hole in durso

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7232.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7232.flv)

Just PVC return - actually the quietest

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7235.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7235.flv)

[llebcire]

I created the teeth with equal 1/4" spacing. The diameter of this 3" reducer is actually 3.5", and the circumference is 12.5". This gives me 25 evenly spaced 1/4" teeth.

Started by figuring:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7236.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7238.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7239.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7240.jpg

Then drilling 1/4" holes - this would have been easier with a table saw and jig!!

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7249.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7250.jpg

For grins I decided to see what type of flow I got

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7252.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7252.flv)

Just the holes could "almost" hadle the flow - but man this thing is noisy!

[llebcire]

Not the prettiest, but I'm hoping black paint and decades of coralline will diminish this fact!

1/4" drill followed by a jig saw - no table saw or dremel on hand.

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7253.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7254.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7255.jpg

Water level

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7257.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7258.jpg

Flow

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7259.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7259.flv)

[llebcire]

As this is noisy, I'm trying to fabricate some sort of noise/gurgle buster along with a cap to keep snails/etc. out while not reducing flow. My recent design follows and I'll eventually fabricate a full cover to keep algae growth down.

The parts:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7304.jpg

My custom overflow, barbed reducer that I sanded the barbs off so it would fit, reducer that's threaded so I can change overflow if needed and cap.

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7305.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7306.jpg

First set of holes. I think I need another but will wait until I have actual flow in leak test.

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7307.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7308.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7309.jpg

There is a small air gap if you look close:

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7310.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7311.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7312.jpg

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7313.jpg

[llebcire]

And a flow test.

Starts with just overflow, then I add insert and finally cap. As a note, it does suck the cap down (siphon) and becomes very quiet! The burping is from underneath the bucket as the other side of the bulkhead is just submerged in water and it letting our air.

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/th_MVI_7320.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/?action=view&current=MVI_7320.flv)

I'll save any more tinkering for the leak test. You can see the turbulance before I install the cap which makes me think I need additional holes in my insert.

I'd also like to make holes further up incase something clogs, but I'm reluctant to add any more airflow at this point.

[EBOLII]

Sweet...I will say though it is difficult to tell any sound difference from the video. What is your evaluation thus far?

[the_blue_tuna_2]

It looked like you had room to put more holes in the insert and still be underwater as the waterlevel rose when you put it in . Nice idea !!

[Sistom]

If you haven't drilled a hole in the bottom yet, you could always consider doing the setup that I used...I found this design somewhere in the forums and it really is a safe, efficient, and silent way to get your water to your sump...I even built my overflow with acrylic and the water level in my display tank never changes...

The down turned elbow on the left is basically only used when starting/stopping my return pump until the level adjusts. It works by creating a siphon when the water level hits the small tube tie strapped to the middle elbow...The middle elbow is just an upturned elbow that allows the water to pour down to the sump…This is also only used during starting and stopping my return until the levels adjust…The far right elbow is a full siphon tube…This is the pipe that does all the work under normal operations…Once a full siphon is created in this pipe, the other two do not have any water running through them…All of these pipes are controlled by valves and by carefully adjusting the pipe on the far right, you can get it to work flawlessly…Mine is only slightly closed and it moves all the water from my main tank to the sump…

So basically, when I start my return pipe, the water gushes over the overflow, breaches the top of the middle bulkhead and all pipes are transferring the water down to the sump…Once the water hits that tube that’s tie strapped to the middle elbow, the left bulkhead creates a siphon, bringing the water down drastically…After less than a minute, the bulkhead on the right will work all the air out of the lines and create a siphon. Once this happens, it transfers enough water that the other two pipes are no longer needed…It really works well and hasn’t failed me yet…Its also silent which is key considering my tank is in my living room…

Just thought I’d throw this idea out there!

Good luck, and let me know if you have any questions…

<img src="http://reefcentral.com/gallery/data/586/198307overflow.jpg" />

<img src="http://reefcentral.com/gallery/data/586/198307Overflow2.jpg" />

[the_blue_tuna_2]

It looked like you had room to put more holes in the insert and still be underwater as the waterlevel rose when you put it in . Nice idea !!

[llebcire]

<a href=showthread.php?s=&postid=14448676#post14448676 target=_blank>Originally posted</a> by Sistom
If you haven't drilled a hole in the bottom yet, you could always consider doing the setup that I used...I found this design somewhere in the forums and it really is a safe, efficient, and silent way to get your water to your sump...I even built my overflow with acrylic and the water level in my display tank never changes...

The down turned elbow on the left is basically only used when starting/stopping my return pump until the level adjusts. It works by creating a siphon when the water level hits the small tube tie strapped to the middle elbow...The middle elbow is just an upturned elbow that allows the water to pour down to the sump…This is also only used during starting and stopping my return until the levels adjust…The far right elbow is a full siphon tube…This is the pipe that does all the work under normal operations…Once a full siphon is created in this pipe, the other two do not have any water running through them…All of these pipes are controlled by valves and by carefully adjusting the pipe on the far right, you can get it to work flawlessly…Mine is only slightly closed and it moves all the water from my main tank to the sump…

So basically, when I start my return pipe, the water gushes over the overflow, breaches the top of the middle bulkhead and all pipes are transferring the water down to the sump…Once the water hits that tube that’s tie strapped to the middle elbow, the left bulkhead creates a siphon, bringing the water down drastically…After less than a minute, the bulkhead on the right will work all the air out of the lines and create a siphon. Once this happens, it transfers enough water that the other two pipes are no longer needed…It really works well and hasn’t failed me yet…Its also silent which is key considering my tank is in my living room…

Just thought I’d throw this idea out there!

Good luck, and let me know if you have any questions…

<img src="http://reefcentral.com/gallery/data/586/198307overflow.jpg" />

<img src="http://reefcentral.com/gallery/data/586/198307Overflow2.jpg" />

I researched this as well, created by BeanAnimal (http://www.reefcentral.com/forums/showthread.php?threadid=1310585) I believe.

As of now, I wanted to go with a single drain and a smaller overflow for lighting - even with an internal glass overflow, it will eventually block light unless it's cleaned often of coralline.

Maybe I'm too concerned with maximizing space in this bowfront - I wanted a bigger tank, she wanted a bowfront for the cosmetics, so here we are!

[llebcire]

<a href=showthread.php?s=&postid=14448665#post14448665 target=_blank>Originally posted</a> by EBOLII
Sweet...I will say though it is difficult to tell any sound difference from the video. What is your evaluation thus far?

I may try and redo the recording as my return is creating noise from the air injection nozzle of my downdraft skimmer - the overflow seems to be virtually silent.

I'm holding off on judgment until I can get this set up for leak testing and really give it a listen.

I realy need to get motivated and stain/finish my stand so I can get going! I can't get motivated to stain as I just spent days hand sanding the old finish.

Here's a pic showing the return just "thrown" into the bucket - I didn't have a reason to break the seal from the nozzle and you can see the air inlet in the pic :D

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Build/Plumbing/IMG_7226.jpg

[llebcire]

So the tank is up and running - finally!

Initially, I had a tremendous amount of noise from the overflow and stockman (external on back of tank), which was mostly eliminated by inserting 1/4" airline. Noise included gurgling and flushing.

Most of the remaining noise is coming from the sump, although I do still have audible flushing about every 5-10 seconds.

I'm losing over a gallon a day, and think that most of this is attributed to the splashing in the sump as I had salt buildup there within the first 24 hours.

Here are a couple of vids from tonight, if you listen you can hear the flushing. Last night I installed a "reverse durso", using a 2" y pipe from the drain. It was better, but I did it late and didn't have time to mess with it before letting it run all night (call me paranoid). In the video, you can see what the bubble trap is doing! Also, at the end you can see the supply to my downdraft skimmer, and every time the drain gurgles it sends bubbles to the skimmer - don't know if this makes a difference to the skimmer or not.

I'll go back to the reverse durso, but what is everyone's results with the drain depth in the sump? It seems that the further underwater the worse the noise!

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Initial%20Setup/th_MVI_7506.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Initial%20Setup/?action=view&current=MVI_7506.flv)

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Initial%20Setup/th_MVI_7511.jpg (http://s4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Initial%20Setup/?action=view&current=MVI_7511.flv)

[EBOLII]

losing over a gallon a day? from a leak or evaporation? If that is Evaporation is that right? seems high

[llebcire]

<a href=showthread.php?s=&postid=14554333#post14554333 target=_blank>Originally posted</a> by EBOLII
losing over a gallon a day? from a leak or evaporation? If that is Evaporation is that right? seems high

Has to be evap - no leaks.

It's only a 72g and 20g sump, both open, no fans. I didn't lose a gallon a day when I ran a 75/30g fuge and 100g sump!

I can only figure it's coming from all the splashing in the sump.

[llebcire]

I created a guage last night to help me monitor evap

http://i4.photobucket.com/albums/y130/llebcire/72%20Bowfront/Initial%20Setup/IMG_7507.jpg