DIY Canopy for 75gal

[gravattj]

A couple of months ago I built a stand for my 75gal tank. I am finally getting around to building the canopy. Typically, I will just build it as I go, but this is complex enough that I figured I better draw it first. Since I am taking the time to draw it, I decided I would post it as well! About a year ago I built a similar canopy for my 125 and was happy with it, but made a few tweaks to the front door for this build.

My goals:

open top for better heat dissapation
holds my light fixture (Coralife 48 Inch Aqualight Pro, 2x150W HQI MH Lamp + 2x96W PC + 3x1W Lunar LED). The dimensions are 48x15 so not a lot of room for error!
easy to open front with easy access inside tank (seems like I am constantly flipping snails over)


I haven't drawn them in, but I hope to add some "flip stay" supports for the door assuming I can find some to work. That's why I added a 1x4 brace on the inside edge of the doors (see below) instead of just putting the 2x4 braces out to the edge.

Notice in the back I moved the lower board up 1/2 inch and added three small feet. This was to accommodate cords for powerheads. Otherwise, I would have to use an extension cord to reach over the board.

I moved the braces behind the door up 1/4 inch to account for opening and closing.

Comments or suggestions welcome!

Front Top
http://gravatt.org/~gravattj/canopy/canopy.front_top.png

Front Bottom
http://gravatt.org/~gravattj/canopy/canopy.front_bottom.png

Back Top
http://gravatt.org/~gravattj/canopy/canopy.back_top.png

Back Bottom
http://gravatt.org/~gravattj/canopy/canopy.back_bottom.png

[gravattj]

Front Right Top
http://gravatt.org/~gravattj/canopy/canopy-dim-front-right-top.png


Front
http://gravatt.org/~gravattj/canopy/canopy-dim-front.png


Top
http://gravatt.org/~gravattj/canopy/canopy-dim-top.png


Back
http://gravatt.org/~gravattj/canopy/canopy-dim-back.png


Bottom
http://gravatt.org/~gravattj/canopy/canopy-dim-bottom.png


Inside Left
http://gravatt.org/~gravattj/canopy/canopy-dim-inside-left.png


Inside Right
http://gravatt.org/~gravattj/canopy/canopy-dim-inside-right.png

[gravattj]

cnt type size purpose
===============================================
3 hinge TBD
1 handle N/A

front
1 2x4 48 1/2 hinge support
2 2x4 10 corner frame
4 1x4 4 1/2 trim
1 1/4 ply 3 1/2 x 10 skin
1 1x4 5 1/4 corner trim (rip in half with tablesaw,
then use router to cut 1/2,
square groove)

front door
2 1x4 9 3/4 braces
3 2x4 9 3/4 braces
2 1x4 41 1/2 trim
1 1/4 ply 41 1/2 x 10 skin

sides
2 2x4 15 1/2 lower frame
4 1x4 19 1/2 trim
2 1/4 ply 19 1/2 x 10 skin

back
2 1x4 9 1/2 corner braces
2 1x4 48 1/2 frame
3 2x4 1/2 feet

[gravattj]

Next step..... the lumber store!

I will post pictures when I start construction.

[csharps42]

Great plan pics, If all goes well you should start selling them. I love woodworking, I built my one stand as well, I just used oak plywood and then trimed it out with oak, looks like a store bought.

[gravattj]

I updated the design and have posted the changes (reflected in the images above). I removed the "feet" and extended the 1x4 boards in back to a full 10".

[gravattj]

fixed dimensions of the side skin

cnt type size purpose
===============================================
3 hinge TBD
1 handle N/A

front
1 2x4 48 1/2 hinge support
2 2x4 10 corner frame
4 1x4 4 1/2 trim
1 1/4 ply 3 1/2 x 10 skin
1 1x4 5 1/4 corner trim (rip in half with tablesaw,
then use router to cut 1/2,
square groove)

front door
2 1x4 9 3/4 braces
3 2x4 9 3/4 braces
2 1x4 41 1/2 trim
1 1/4 ply 41 1/2 x 10 skin

sides
2 2x4 15 1/2 lower frame
4 1x4 19 1/2 trim
2 1/4 ply 18 1/2 x 10 skin

back
2 1x4 9 1/2 corner braces
2 1x4 48 1/2 frame
3 2x4 1/2 feet

[gravattj]

Cut your lumber.

I made the mistake of precutting the front "corner trim" pieces before using the router to cut the 1/2" grooves. I recommend cutting a 1x4 piece about 16" long, rip it down to 3/4" wide with a table saw, use a router to cut the 1/2" grooves, then use a miter saw to cut to 5 1/4 length.

https://www.gravatt.org/~gravattj/canopy/step1/2010-11-18.jpg

[gravattj]

Round the corners of your trim with a router. Make sure you only round the edges that will be facing out.


front - trim (don't round the corner trim)
front door - trim
sides - trim


https://www.gravatt.org/~gravattj/canopy/step2/2010-11-19_11-39-01_946.jpg

https://www.gravatt.org/~gravattj/canopy/step2/2010-11-19_11-39-05_496.jpg

https://www.gravatt.org/~gravattj/canopy/step2/2010-11-19_11-39-20_212.jpg

[gravattj]

Build the back.

Round up your pieces and sand them.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_11-59-57_285.jpg

Using some clamps, rubber hammer, and a sqaure, start dry fitting.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_12-04-17_82.jpg

After squaring both ends, pre drill pilot holes.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_12-19-14_500.jpg

Use a countersink to help keep the wood from splitting.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_12-20-23_701.jpg

Put in one screw per corner.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_12-23-04_917.jpg

Double check for square and put in a second screw in each corner.
https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_12-24-30_868.jpg

https://www.gravatt.org/~gravattj/canopy/step3/2010-11-19_14-09-33_837.jpg

[gravattj]

Assemble the sides.

Start with the 2x4 pieces. Give them a quick sanding.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-24-34_672.jpg

Using some clamps, I secured the bottom board to my workbench.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-27-13_609.jpg

Predrill 1 pilot holes into the front board.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-27-23_475.jpg

Fasten with a screw. We will add a second screw later.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-27-52_746.jpg

Attach the skin. First check for square.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-36-43_554.jpg

I used a staple gun with 5/8" brads.
https://www.gravatt.org/~gravattj/canopy/step4/2010-11-19_14-34-57_333.jpg

[gravattj]

Attach back to sides.

Drill two pilot holes in lower board on each end. START the screws. Put the sides on the floor face down. Then rest the back on top of them.
https://www.gravatt.org/~gravattj/canopy/step5/2010-11-19_14-50-31_961.jpg

Check for square and drill one of the screws in. Repeat for other side.
https://www.gravatt.org/~gravattj/canopy/step5/2010-11-19_14-50-33_791.jpg

Drill in the remaining two screws.

https://www.gravatt.org/~gravattj/canopy/step5/2010-11-19_14-51-36_62.jpg

Flip stand over.
https://www.gravatt.org/~gravattj/canopy/step5/2010-11-19_14-55-41_955.jpg

Put in a second screw into the front two boards. Be sure to check for square again.
https://www.gravatt.org/~gravattj/canopy/step5/2010-11-19_14-56-42_995.jpg

[gravattj]

Attach front brace.

Set canopy upside down on the floor. Place brace into location.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_14-58-48_64.jpg

Use clamps to temporarily hold in place.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_14-59-49_651.jpg

Optional - I added weights to try to ensure canopy was as square as possible. Drill one screw into each end.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_15-00-39_680.jpg

Flip over and check for square.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_15-03-38_750.jpg

I used clamps on the square to hold it in place.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_15-04-56_274.jpg

Drill in second screw on each end.
https://www.gravatt.org/~gravattj/canopy/step6/2010-11-19_15-05-32_139.jpg

[gravattj]

Dry fit onto aquarium and make adjustments if necessary. Additionally, I test fitted the light. In my case I have to put it in at angle (front down first) in order to clear the brace.

https://www.gravatt.org/~gravattj/canopy/step7/2010-11-20_09-19-15_851.jpg

I wasn't quite square so I had to back out one of the screws on the front. I used the clamps+square approach to fix it.
https://www.gravatt.org/~gravattj/canopy/step7/2010-11-20_09-46-08_383.jpg

https://www.gravatt.org/~gravattj/canopy/step7/2010-11-20_09-42-45_135.jpg

[gravattj]

Counterpunch brads and sand the side skins.

https://www.gravatt.org/~gravattj/canopy/step8/2010-11-20_09-26-12_717.jpg

https://www.gravatt.org/~gravattj/canopy/step8/2010-11-20_09-26-55_960.jpg

[gravattj]

Attach front skin, counterpunch, and sand.

https://www.gravatt.org/~gravattj/canopy/step9/2010-11-20_09-38-15_101.jpg

[gravattj]

Attach trim to front and sides.

Miter the corners (45 degree angle of course) and sand prior to fastening.

Attach trim with clamps and measure carefully.
https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-14-15_214.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-14-25_185.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-23-41_850.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-23-50_619.jpg


I drilled pilot holes to make it easier to attach trim. Then I used 4d finish nails. Don't forget to counterpunch the nails.
https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-24-01_790.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_10-30-45_288.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_11-34-37_21.jpg

https://www.gravatt.org/~gravattj/canopy/step10/2010-11-20_11-34-46_554.jpg

[gravattj]

Begin assembly of the front door.

Attach the trim pieces to the skin using 5/8" brads.
http://www.gravatt.org/~gravattj/canopy/step11/2010-11-20_11-46-44_540.jpg

http://www.gravatt.org/~gravattj/canopy/step11/2010-11-20_11-49-10_250.jpg

[gravattj]

Dry fit front door.

I used a table saw to shave off a fraction of an inch.
http://www.gravatt.org/~gravattj/canopy/step12/2010-11-20_11-50-30_626.jpg

[gravattj]

Finish assembly of front door.

Attach 1/4s to outside edges.
http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_11-53-20_9.jpg

Don't forget to leave 1/4" at the bottom for clearance.
http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_11-53-28_64.jpg

Drill pilot holes and countersink to avoid splitting.
http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_11-57-04_325.jpg

Dry fit.
http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_11-58-44_898.jpg

Attach 2x4 braces.
http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_12-00-23_312.jpg

http://www.gravatt.org/~gravattj/canopy/step13/2010-11-20_12-00-28_207.jpg

[gravattj]

Attach front door.

I used clamps to dry fit it.
http://www.gravatt.org/~gravattj/canopy/step14/2010-11-20_13-41-29_496.jpg

I pushed the bottom in just slightly to make sure the door closes flush with the frame.
http://www.gravatt.org/~gravattj/canopy/step14/2010-11-20_13-41-37_93.jpg

Attach 3" hinges to 2x4 door braces and front 2x4 brace.
http://www.gravatt.org/~gravattj/canopy/step14/2010-11-20_13-56-10_737.jpg

[gravattj]

Test that the door opens and closes properly. Make adjustments as necessary.

http://www.gravatt.org/~gravattj/canopy/step15/2010-11-20_13-56-01_414.jpg

http://www.gravatt.org/~gravattj/canopy/step15/2010-11-20_14-59-46_115.jpg

http://www.gravatt.org/~gravattj/canopy/step15/2010-11-20_14-59-57_748.jpg

http://www.gravatt.org/~gravattj/canopy/step15/2010-11-20_15-00-11_445.jpg

[gravattj]

Test fit on aquarium. Tweak as necessary.

http://www.gravatt.org/~gravattj/canopy/step16/2010-11-20_15-06-03_333.jpg

http://www.gravatt.org/~gravattj/canopy/step16/2010-11-20_15-06-11_813.jpg

http://www.gravatt.org/~gravattj/canopy/step16/2010-11-20_15-07-15_177.jpg

[gravattj]

Attach corner trim. Use Pilot holes and countersink.

http://www.gravatt.org/~gravattj/canopy/step17/2010-11-21_09-00-33_266.jpg

http://www.gravatt.org/~gravattj/canopy/step17/2010-11-21_09-01-56_384.jpg

[gravattj]

Sand thoroughly.

[gravattj]

Stain everything EXCEPT the inside. Apply sealer (I did 3 coats) to protect against moisture.

[gravattj]

Paint the inside (2 coats) with Kilz.

[gravattj]

http://www.gravatt.org/~gravattj/canopy/finished/2010-12-05_13-34-58_765.jpg

http://www.gravatt.org/~gravattj/canopy/finished/2010-12-05_13-35-23_7.jpg

http://www.gravatt.org/~gravattj/canopy/finished/2010-12-05_13-35-38_6.jpg

http://www.gravatt.org/~gravattj/canopy/finished/2010-12-05_13-35-47_54.jpg