156 Gallon Foam Rock Wall and In-Wall Build

[giants4pc]

I would like to document the progress of the this project. I really got the idea and motivation from Speckled Grouper. Her thread and help is really what I am going by. It will be slow moving to get the tank up and running in-wall, but I plan on constructing the foam rock wall in the coming weeks. This will be an upgrade from my current 90 gallon in-wall. Here are some preliminary photos:

156 Gallon 60 x 24 x 25 Oceanic. It is used with a nice dark blue background. I plan on using 2-3 Vortechs so I will leave the cutouts for those. Even if I don't use three, I think it will be pretty cool to see the dark background.
http://i24.photobucket.com/albums/c35/giants4pc/P1010163.jpg

http://i24.photobucket.com/albums/c35/giants4pc/P1010164.jpg

I have all the material on order. I will first begin by framing out the eggcrate. My intention is to use two pieces for the back and two pieces each for each overflow.

[giants4pc]

Started making the rock part of the wall this evening. I have some rock on order so I don't want to do too much until I see what I have to work with. The basic shape of it with eggcrate is done as well as some of the rock mounting.
http://i24.photobucket.com/albums/c35/giants4pc/DSC04838.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04839.jpg

Obviously there is still a great deal of rock to add before foaming.

[giants4pc]

I got 40 lbs of Marco rock in today. So, the zip tie part of the project is nearly complete. I still have more rubble that I plan to just lay down when I am ready to foam. Here are some shots of how the rock looks tied to the eggcrate.
http://i24.photobucket.com/albums/c35/giants4pc/DSC04847.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04848.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04849.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04850.jpg

I should be getting the foam tomorrow. Next step is to lay the structures down and start foaming. This will secure the crate and give it that stability. I can then mold the foam to my liking.

[ddeneve]

You should see how much water the foam wall displaces, just because I'm curious.

[wtildens]

Nice tank, I'll be following along.

[giants4pc]

You should see how much water the foam wall displaces, just because I'm curious.

I'm not happy about that. I was hoping to go bigger than 156 just for that reason, but ultimately, the fish room behind it is only going to be 4 feet wide so I had to live with it. 4 feet in width is better than no fish room at all. I don't have a lot of rock in my current 90 so I am hoping that by using this on the back and taking only what I have now, it will still leave plenty of room for swimming space and coral growth.

[EnderG60]

PUT MORE ROCKS ON! it will float like it is now trust me!

[giants4pc]

PUT MORE ROCKS ON! it will float like it is now trust me!

Did you silicone it to the back glass though? By my observations, according to the original thread that I followed, I have just as much, if not more, than Speckled Grouper. I am in no rush at all, so I think using a great deal of silicone on the back and letting it dry properly will be sufficient to keep it down.

[giants4pc]

I started foaming today. I used four cans - one for each piece. Since I ordered five, I should be good once they are fitted into place. The last can can be used to close the seams and touch up any area I missed. You definitely need to wait a good 30 minutes for the foam to become tacky - otherwise, it just creates a mess. I will wait a good 24 hours now, fit them into place in the tank, cut the excess, wait another day or two, then start the epoxy step.
http://i24.photobucket.com/albums/c35/giants4pc/DSC04883.jpg
http://i24.photobucket.com/albums/c35/giants4pc/DSC04884.jpg
http://i24.photobucket.com/albums/c35/giants4pc/DSC04882.jpg
http://i24.photobucket.com/albums/c35/giants4pc/DSC04881.jpg

[giants4pc]

Structures cut to tank layout. Overflow structures had to be cut in half. I really want to silicone all pieces to the back, so that is why I am doing this now. Next, epoxy and apply substrate to remove the eye sore that is the stark black of the foam. I am liking it very much so far - pictures don't do it justice.
http://i24.photobucket.com/albums/c35/giants4pc/DSC04896.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04898.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04895.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04900.jpg

Once it has all been siliconed, I will touch up the foam with the corners and so on...

[customcolor]

the white rocks will get darker and the pond foam will get grayer...all in all...in 6-9 months you wont be able to sell the difference by color alone

[giants4pc]

Epoxied and added the substrate earlier this evening. Here are some pics:

http://i24.photobucket.com/albums/c35/giants4pc/DSC04911.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04912.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC04913.jpg

Now I need to let them dry. I didn't go through nearly as much substrate as I thought. This is fine though - I will keep it for the bottom once I get the tank up and running. Next, after they dry is to epoxy the backside just to be sure. Then, fit them into the tank, silicone them in place, foam the crevices and joints, epoxy any foam, and apply the rest of the substrate. It is a fun project that is looking very good.

[Gillundr]

NICE WORK! I'm just curious, did you make any caves through the foam? I always wondered about doing a foam wall build and thought it would be cool to put in some rubber hose or pvc and zip tie that in then foam around it to make caves and stuff. With a rubber hose you could make it turn a corner and use a Y in there to branch off or something. I'm not sure how well it would work but always wanted to try it out.
Great Job, I can't wait to see the end results! Makes me want to try it.

[giants4pc]

NICE WORK! I'm just curious, did you make any caves through the foam? I always wondered about doing a foam wall build and thought it would be cool to put in some rubber hose or pvc and zip tie that in then foam around it to make caves and stuff. With a rubber hose you could make it turn a corner and use a Y in there to branch off or something. I'm not sure how well it would work but always wanted to try it out.
Great Job, I can't wait to see the end results! Makes me want to try it.

I thought about making caves with plastic bottles and/or pvc couplings and stuff like that, but ultimately I did not. I stuck with just the rock and foam. I did make several ledges, but nothing in the sense of distinct openings. I have enough rock from my current 90 to make it look deeper than it actually is, and that is what I wanted from the start. Here are some completed pics. They aren't the best quality, but I can say with certainty that I am very pleased. I now need to touch up some spots where the sand didn't stick well, but as is, it's about 95% done.

Left side:
http://i24.photobucket.com/albums/c35/giants4pc/DSC04950.jpg

Right side:
http://i24.photobucket.com/albums/c35/giants4pc/DSC04951.jpg

Center:
http://i24.photobucket.com/albums/c35/giants4pc/DSC04952.jpg

front view :
http://i24.photobucket.com/albums/c35/giants4pc/DSC04952.jpg

Angled front shot -disregard the two stand alone pieces in front:
http://i24.photobucket.com/albums/c35/giants4pc/DSC04953.jpg

As I mentioned in the first post, this will be an eventual in-wall build, but that is on hold for quite some time. I will take a long time to slowly cure this.

[NanoReefWanabe]

foam wall and dry rock need no "curing" so to speak...only cycling..

[giants4pc]

Yah, I just figured in the months that I am waiting for the house to be built, I might as well get some used saltwater in there from water changes and get some water flow. It can't hurt.

[kayaking2]

I'm tagging along. I love watching DIY projects like this. The rock wall came out looking pretty good. Can't wait for you to get water in there with some fish and corals.

[lusenut2]

Im tagging along for the build. I just started the foam wall for my 120 yesterday.

[lusenut2]

What Exopy did you use?

[marc111]

I would like to offer one suggestion; Try to break up the rectangular outlines a bit. Nature rarely has straight lines. A few rocks poking out and around vertical corners along with foam contours that round the corners can do wonders for making things look more natural.

Mark

[lusenut2]

Any updates yet?

[T Diddy]

Any updates yet?

what he said...I'm in the middle of my own buildthread now on reef discussion. Any updates or tips are appreciated.

[giants4pc]

I will post a pic soon. It's done and sitting in a basement ready to be put to good use.

[~sp0ok~]

nice work..im doing my wall now....

http://i52.*******.com/fdav5w.jpg

http://i52.*******.com/10qwh8i.jpg

http://i54.*******.com/250nfns.jpg

http://i53.*******.com/2zxxe9d.jpg

sry just wanted to show you:dance:

[lusenut2]

How is the tank doing?

[giants4pc]

I think it's about time to revisit and add to this thread. The tank has been sitting idle for several months while my new house has been under construction. I didn't do anything to it except cycle it through with sand and some rock. The house is in the finishing stages and I am getting ready to transfer the tank there so the carpenter can put the molding around the tank the right way.

My wife and I made a deal. I get a fish room and she gets a huge walk-in closet. Who was I to complain. I wish my room was wider, but it will have to do. I was able to get a fish room built into the plans of a new house...can't complain too much. The room is 4x25. I will be transferring the tank over there in the next couple days, so I took a couple of picks first to show where it will be going.

http://i24.photobucket.com/albums/c35/giants4pc/DSC00210.jpg
Family room shots - open floor plan so this view is in between the kitchen and family rooms.
http://i24.photobucket.com/albums/c35/giants4pc/DSC00209.jpg
Fish room
http://i24.photobucket.com/albums/c35/giants4pc/DSC00211.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00212.jpg

[T Diddy]

How recent are those shots of the fish room? You may consider plumbing a floor drain and possibly an exhaust fan. I haven't yet needed the floor drain, but it sure would be nice to have for water changes, sump cleaning, unforseen disasters, etc. The exhaust fan will help with humidity/heat issues.

Looking good so far...Hurry up and get some water in there! :bounce2:

[on the spot]

How recent are those shots of the fish room? You may consider plumbing a floor drain and possibly an exhaust fan.

I see a stub out for a sink, so I'd say that will have to do. I'd second the vent.

[kayaking2]

no pictures of the wife's walk in closet:-)

[Scott B]

nice, im jealous, good luck!

[giants4pc]

I do have a deep sink in the corner for water change purposes. I thought that was a better route than a floor drain. I also have heat and ac in there for venting so that should take care of that issue.

I will take a pic of the closet. It's not quite as involved, but I think 70 sq ft will be enough. She only has a mere 130 pairs of shoes....
I will take a pic once it has the shelving up.

I transferred the tank today and put water in it. I have a remora skimmer and powerhead just to keep the rock submerged and cycled through. The electrician hasn't put the plugs yet, so the entire system has not yet been plumbed. I will have a 75 gallon sump underneath and my old 90 gallon for extra water volume plumbed next to it. Not pics though...forgot the camera. I will take some tomorrow.

[T Diddy]

I do have a deep sink in the corner for water change purposes. I thought that was a better route than a floor drain. I also have heat and ac in there for venting so that should take care of that issue.



I'd still consider the exhaust fan and vent. The HVAC will not be sufficient unless you keep your fish room door open all the time. I am going to add one to my fish room pretty soon.

Good luck with the rest of your build! I'm tagging along

[giants4pc]

Time to revisit after being extremely busy with the move. Tank is settling in nicely. I am running through a slight cycle right now - brown stringy algae. All in all though, I really like the way the rock wall looks. I can't wait for it to color up. My camera isn't the greatest, but you get the idea.
http://i24.photobucket.com/albums/c35/giants4pc/DSC00430.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00437.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00433.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00437.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00438.jpg

Fish room with newly installed vented return:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00434.jpg

Water changing station still in the works:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00436.jpg

And, per request, a shot of the shoe rack - this picture doesn't do it justice:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00448.jpg

[dzfish17]

Nice in wall set-up. The rockwall looks great.

[giants4pc]

Can't wait to get some fish and start stocking.

[IDrawFish]

::Gasp:: (Breath taken away) awesomeness... So the second tank could be a large QT tank but what's in the biocube?

[giants4pc]

I don't plan on using the 90 gallon as a QT - I just wanted it for extra water volume and live rock. It is plumbed into the system. The biocube just has a small clown right now. I want to get something different in there.

[sweet d]

nice setup am very jealous love the rock wall!

[bmullikin1]

looks like your other half has you by a few dozen shoes.

[giants4pc]

I don't have one pair in there...

[loki32687]

That looks great, good work.

[lusenut2]

How is the tank doing?

[woody311az]

Yeah, an update on the tank would be cool.

[giants4pc]

Tank is really starting to shape up. It took some time to balance alk and calcium dosing. I will take some pics later tonight. I am horrible with the camera, but it will show progress. Rock wall is coloring up nicely.

[giants4pc]

Update:

First set up in April:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00433.jpg

Today:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00916.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00919.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00914.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00915.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00922.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00924.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00925.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00926.jpg

For some reason my caps aren't doing well but other than that, things are good. I'm keeping alk between 9-10, calcium 440-450, mag 1350-1400.

[giants4pc]

Any feedback?

[raylost]

I like it a LOT! Great setup

[SPCLMANAGE]

Very nice setup. Do you have the spectrapure filling up your ATO unit with a float or just when needed for water changes. Good job taking the time to plan things out during the build and not rushing like so many.

[N-A-S-O]

Very nice. I just built a wall for my new tank. Can't wait to get it all set up.

[giants4pc]

Very nice setup. Do you have the spectrapure filling up your ATO unit with a float or just when needed for water changes. Good job taking the time to plan things out during the build and not rushing like so many.

I will take a pic of my water change station later on. I do not use a float switch. I sort of rigged a homeade device that will empty into the sink should I forget to shut the water off. But, it's pretty simple and allows for very quick water changes. On the tank itself, I have a Tunze osmolator that works great.

[giants4pc]

Here is an update of the filtration room. I won't complain because I realize having a fish room is a luxury, but it is only 4 feet wide, so there is a space constraint. I used to use two slim jim waste barrels, but the saltwater one was just too small. So, I recently upgraded and found a used 40 gallon tank that I now use for the saltwater. It looks a bit messy with the wires until I figure out how best to organize them. It's pretty simple though. I simply drain 20 gallons from the tank into the sink, then hook up some vinyl tubing and plug in a pump. Takes a few minutes to do a 20 gallon water change.
http://i24.photobucket.com/albums/c35/giants4pc/DSC00942.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00943.jpg

drain area and skimmer. Octopus SRO2000 internal:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00946.jpg

Bad side view with lights off - taken from fish room-
http://i24.photobucket.com/albums/c35/giants4pc/DSC00945.jpg

external pump connecting two tanks together:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00948.jpg

http://i24.photobucket.com/albums/c35/giants4pc/DSC00949.jpg

Full shot of room - 25'x4'
http://i24.photobucket.com/albums/c35/giants4pc/DSC00950.jpg

lights:
http://i24.photobucket.com/albums/c35/giants4pc/DSC00951.jpg

[giants4pc]

I am a little disappointed with the light penetration in the center. I know I only have a regular parabolic on there with an older Radium bulb, but the look of the tank prior to adding this third light is almost unnoticeable. There seems to still be a shadow cast in the middle. Clearly, 3 250w bulbs over a 5' tank are more than adequate. Strange...