100 gal sump project/build

peppie · 05/02/2012, 09:06 PM

I bought two of these from a local reefer.
Each is a 100 gal 3/8'' acrylic. they are divided in the center making two 50 gal compartments.
One will be used for a sump the other will be a frag tank/ QT tank. The frag part will be plumbed into the sump and DT. The QT will have separate filtration.

I started off by adding some gussets to the inside corners of the sump. IMO 3/8' material is a little thin for my liking.

First section is going to be for a sock holder. The overflow box has to go.

divider wall

Tools for my holes and edges

some pre assembly

This little short wall will help keep the water in long enough to let the pellet reactor pump to draw in raw DT water

peppie · 05/02/2012, 09:18 PM

Lets keep it going
This was my first thought for the top

Needless to say that plan changed

I found out from some research that it would be better to have full access to the sock installation
So a little jigsaw work fixed that part

reshaped the top holder

I will use 2 4'' collared felt socks

I cut a dado in the semi circle for the 4'' plastic collar of the sock to sit down into

gluing the top on

from top down

peppie · 05/02/2012, 09:31 PM

So as mentioned before the DIY pellet reactor will sit next to the sock holder and be driven by a 500gph pump the will feed the skimmer

Next up will be an air driven counter current DIY skimmer

drktemplar · 05/03/2012, 12:01 AM

nice looking good

peppie · 05/03/2012, 05:24 PM

Thanks drk,
I am not to sure it looks good!!! LOL I just want it to work great!! And not look like a 5 year old built it.
Sometimes I find myself having to resort to plan B.

kory1006 · 05/03/2012, 07:05 PM

Did you do most of your cutting and shaping with the Dremel and jigsaw? If so, it looks pretty damn good.

peppie · 05/03/2012, 07:26 PM

Quote:

Originally Posted by kory1006

Did you do most of your cutting and shaping with the Dremel and jigsaw? If so, it looks pretty damn good.

All inside circles thus far have been cut with the jigsaw, and then the sharp edge has been removed with the dremel. I used a roll of tape to trace the curves.

All of the edges that need to be welded are ran thru the tablesaw, and then I take about 1/64'' of at the router table to dress the edge.

Thanks, kory

peppie · 05/04/2012, 10:50 PM

I got a little time to work on the skimmer today. I got started buy roughing out the circles and some flange material, then put them to the router table to make a true circle and clean the edges.

I used a V point cutter to make the gasket groove

1 of 2 flanges laid out ready to drill

I will use 3/8'' nylon bolts to hold them together
a bit of tapping needs to be done

1 down (the small one) 1 to go ( the large one)

peppie · 05/08/2012, 06:01 PM

So all of the round bases and flanges are done with the exception of rounding over the sharp edges.
Today I jigged up to prep the tubes to weld them to the bases and flanges.
I will have 6'', 8'', 10'', and 12'' tubes for the skimmer body.
I started with the 6'' and will work my way up to the 12''
This is the bottom of the jig. The tube will stick out the bottom about 1/4''. The thin strips of wood will allow me to raise the router bit above the top of the router table.

I set the tube on some shims and screwed some corner braces to the base of the jig, and right up against the tube

put a strap clamp around it to hold it in place

Run on the router table, then flip the tube and cut the other end

ready to weld

Made sure it was some what square, Didnt want the leaning tower of skimmer.

peppie · 05/09/2012, 06:14 PM

Made progress today
Rounded over the bases and flanges

Glued up the flange to the neck

This will give you an idea of the diam.

This will be part of the mixing chamber. It will set on top of a 15'' X 15'' box built into the sump

The welds came out quite nice

This will give you and idea of the soon to be finished height. The ruler is 36''.

There is still so much to do!!

peppie · 05/23/2012, 08:27 PM

After a bit of thought I decided I didnt like the transitions from the 12'' tube to the 6'' neck.
I did some research and decided to make a cone.
I built a jig to plunge a 6'' tube into a 14'' diam. piece of 3/8'' acrylic.
This is the result

I made a jig to flatten the top, and cut the flange off.
I think this will help the bubbles and foam make a much better transition opposed to the wedding cake design

Still need to add a couple of flanges, But you get the idea.

yellowRubi · 05/24/2012, 06:26 AM

all i got to say is WOW! Great job! I wish to have a router table like this... i have a little Bosch Roter table wich kinda sucks.... Did u buy the whole table somewhere? Or you can buy just the top ?

muttley000 · 05/24/2012, 07:29 AM

Hey Peppie! Don't get to Reef Central so much any more, but just found this. Great work just like all of your other projects! Can we see the jig you made the cone with?
Matt

wastedtime · 05/24/2012, 07:41 AM

Wow this is an amazing project, I've worked with acrylic before and i know it isnt easy. You make this look incredibly easy.

peppie · 05/24/2012, 07:02 PM

Quote:

Originally Posted by yellowRubi

all i got to say is WOW! Great job! I wish to have a router table like this... i have a little Bosch Roter table wich kinda sucks.... Did u buy the whole table somewhere? Or you can buy just the top ?

Thanks Yellow,
As you can see in some of my pics my shop is not very big, so to save space I made the table myself and attached it to the table saw with a piano hinge. That way I can fold it down out of the way when not in use.
I would like to get a different set up so I can adjust it easier.

peppie · 05/24/2012, 07:20 PM

Quote:

Originally Posted by muttley000

Hey Peppie! Don't get to Reef Central so much any more, but just found this. Great work just like all of your other projects! Can we see the jig you made the cone with?
Matt

Hey Mutt,
I see you here every once and a while. I hardly ever stray from the DIY forum.
This is just the start to a 400gal+ build I hope to have finished by next summer. Stay tuned I am going to build a glass tank with closed loop. 60'' long 30'' front to back and 30'' tall. I will have the sump and frag/ QT in the garage.

Sorry I didnt get any pics of the jig. I was very simple. I cut 2 14'' diam circles out of 3/4'' plywood. The bottom circle had a 12'' hole cut in the center. the top circle had a 6'' hole cut in the center. I placed the acrylic between them and screwed the sandwich together about every 2''.
So all I needed to do was find a trash can, or something that had a diam between 12''-14''.to hold the jig off the ground while I plunged a 6'' tube thru the 6'' hole cut in the top circle.
I had to take the whole ball of wax to a buddies house to form it, he has the oven. I left the jig there.

peppie · 05/24/2012, 07:24 PM

Quote:

Originally Posted by wastedtime

Wow this is an amazing project, I've worked with acrylic before and i know it isnt easy. You make this look incredibly easy.

Thanks Wasted.
I have worked wood for many years, and acquired many wood working tools. I found the transition to acrylic was fairly easy as the tools serve as switch hitters.
I have only been playing with acrylic for about 2 years and lovin every min of it.

wastedtime · 05/25/2012, 06:37 AM

Quote:

Originally Posted by peppie

Thanks Wasted.
I have worked wood for many years, and acquired many wood working tools. I found the transition to acrylic was fairly easy as the tools serve as switch hitters.
I have only been playing with acrylic for about 2 years and lovin every min of it.

You can do so many things with acrylic. I used to mod computer cases as a hobby. Having the right tools with acrylic is the most important, Great job so far, I am following this.

peppie · 05/25/2012, 09:57 PM

So I cleaned up the top and bottom of the cone and then I thought it best to flatten them before I welded them to the flanges
You can see the low spots

I glued some 120 grit to a piece of acrylic and got to work

Pins in place and ready to weld

Drilled a hole for a 3/4'' uniseal and shoved some 1/2'' fittings in there for water in

Bought some 1/2'' spa flex and layed out 5 segments

Cut 4 slots

Set up a test

Water on

Not to sure I like this. Will try plan B tomorrow.

Metal Man 1221 · 05/25/2012, 11:56 PM

great work on the skimmer!

peppie · 05/26/2012, 11:46 AM

Thanks 1221,

Well plan B was a bust!!!!

I thinks I am on to something withthe Loc-line.
Plan B-1a, up next

peppie · 05/27/2012, 10:36 AM

Here is plan B-1a, LOL
I like the flow pattern of this plan, it will also be very easy to adjust. I drilled holes in the loc-line. just a twist here and there wil direct the flow toward the center. The pump is a mag 5 @ 500gph

feruz · 05/27/2012, 11:02 AM

great work...

wastedtime · 05/29/2012, 02:51 PM

If I were you I would just keep it in the backyard as a nice water feature. Looks great.

peppie · 05/29/2012, 07:24 PM

I am not sure the wife likes the upsidedown plastic thing look for a fountain. LOL

Did a little work today on the cup neck. The twist lock approach was what I chose to use.
It is simple to make and it will be easy on easy off.

05/02/2012, 09:06 PM	#1
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	100 gal sump project/build I bought two of these from a local reefer. Each is a 100 gal 3/8'' acrylic. they are divided in the center making two 50 gal compartments. One will be used for a sump the other will be a frag tank/ QT tank. The frag part will be plumbed into the sump and DT. The QT will have separate filtration. I started off by adding some gussets to the inside corners of the sump. IMO 3/8' material is a little thin for my liking. First section is going to be for a sock holder. The overflow box has to go. divider wall Tools for my holes and edges some pre assembly This little short wall will help keep the water in long enough to let the pellet reactor pump to draw in raw DT water

05/08/2012, 06:01 PM	#9
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	So all of the round bases and flanges are done with the exception of rounding over the sharp edges. Today I jigged up to prep the tubes to weld them to the bases and flanges. I will have 6'', 8'', 10'', and 12'' tubes for the skimmer body. I started with the 6'' and will work my way up to the 12'' This is the bottom of the jig. The tube will stick out the bottom about 1/4''. The thin strips of wood will allow me to raise the router bit above the top of the router table. I set the tube on some shims and screwed some corner braces to the base of the jig, and right up against the tube put a strap clamp around it to hold it in place Run on the router table, then flip the tube and cut the other end ready to weld Made sure it was some what square, Didnt want the leaning tower of skimmer. Last edited by peppie; 05/08/2012 at 06:05 PM. Reason: switch pic

05/24/2012, 06:26 AM	#12
yellowRubi ~~~POLSKA~~~ Join Date: May 2006 Location: Streamwood,IL Posts: 471	all i got to say is WOW! Great job! I wish to have a router table like this... i have a little Bosch Roter table wich kinda sucks.... Did u buy the whole table somewhere? Or you can buy just the top ? __________________ ~~~ up and running and cycle started on 9-3-2011 ~~~ ~~~ 57Gal Illumina ~~~ APEX w/all the goodies ~~~ MP40w ~~~ MP10W~~~ ~~~ Eheim 1262 ~~~ SWC 160 skimmer ~~~ 35Gal Nanoseacreations sump ~~~ ~~~ATI 6x39 Dimmable SunPower~~~ 2LittleFish reactor x2 ~~~ 500W heater ~~~

05/24/2012, 07:29 AM	#13
muttley000 Registered Member Join Date: Feb 2005 Location: NW Ohio Posts: 1,421	Hey Peppie! Don't get to Reef Central so much any more, but just found this. Great work just like all of your other projects! Can we see the jig you made the cone with? Matt __________________ 29 gallon Display with 29 gal sump 40 pounds Bali Alor rock 6" RDSB in rubble and macro fuge Aqua C EV120 Skimmer w/mag 5 mag 7 return w/ glass*holes 1500 overflow MP10 for circulation Hamilton 175 W 10000K w/1 T5 actnic and 1 10K T5 Custom Stand and Hood Current Tank Info: 29 gal reef, 65 fowler, 5 gal nano, 17 gal Nemo Pair. 40 Breeder, 40 standard, 37 cube, 30 gal, 47 bow, 20 long all empty right now

05/25/2012, 11:56 PM	#20
Metal Man 1221 FMMAS Executive Director Join Date: Aug 2009 Location: Fargo ND Posts: 1,198	great work on the skimmer! __________________ "My advise is, always look at their aquarium before you take their advise. Because alot of people give advise and they havnt got a clue" ~David Saxby~ "Only after the last tree's cut and the last river poisoned only after the last fish is caught will you find that money cannot be eaten" ~Lamb of God~ Current Tank Info: 125g DT, 45g sump ---- 57g Illuminata, custom sump

05/02/2012, 09:18 PM	#2
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	Lets keep it going This was my first thought for the top Needless to say that plan changed I found out from some research that it would be better to have full access to the sock installation So a little jigsaw work fixed that part reshaped the top holder I will use 2 4'' collared felt socks I cut a dado in the semi circle for the 4'' plastic collar of the sock to sit down into gluing the top on from top down

05/02/2012, 09:31 PM	#3
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	So as mentioned before the DIY pellet reactor will sit next to the sock holder and be driven by a 500gph pump the will feed the skimmer Next up will be an air driven counter current DIY skimmer

05/03/2012, 12:01 AM	#4
drktemplar Registered Member Join Date: Mar 2012 Location: maryland Posts: 55	nice looking good

05/03/2012, 05:24 PM	#5
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	Thanks drk, I am not to sure it looks good!!! LOL I just want it to work great!! And not look like a 5 year old built it. Sometimes I find myself having to resort to plan B.

05/03/2012, 07:05 PM	#6
kory1006 Registered Member Join Date: Sep 2011 Location: Florida Posts: 84	Did you do most of your cutting and shaping with the Dremel and jigsaw? If so, it looks pretty damn good.

05/04/2012, 10:50 PM	#8
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	I got a little time to work on the skimmer today. I got started buy roughing out the circles and some flange material, then put them to the router table to make a true circle and clean the edges. I used a V point cutter to make the gasket groove 1 of 2 flanges laid out ready to drill I will use 3/8'' nylon bolts to hold them together a bit of tapping needs to be done 1 down (the small one) 1 to go ( the large one)

05/09/2012, 06:14 PM	#10
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	Made progress today Rounded over the bases and flanges Glued up the flange to the neck This will give you an idea of the diam. This will be part of the mixing chamber. It will set on top of a 15'' X 15'' box built into the sump The welds came out quite nice This will give you and idea of the soon to be finished height. The ruler is 36''. There is still so much to do!!

05/23/2012, 08:27 PM	#11
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	After a bit of thought I decided I didnt like the transitions from the 12'' tube to the 6'' neck. I did some research and decided to make a cone. I built a jig to plunge a 6'' tube into a 14'' diam. piece of 3/8'' acrylic. This is the result I made a jig to flatten the top, and cut the flange off. I think this will help the bubbles and foam make a much better transition opposed to the wedding cake design Still need to add a couple of flanges, But you get the idea.

05/24/2012, 07:41 AM	#14
wastedtime Registered Member Join Date: Jan 2012 Location: Massachusetts Posts: 72	Wow this is an amazing project, I've worked with acrylic before and i know it isnt easy. You make this look incredibly easy.

05/25/2012, 09:57 PM	#19
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	So I cleaned up the top and bottom of the cone and then I thought it best to flatten them before I welded them to the flanges You can see the low spots I glued some 120 grit to a piece of acrylic and got to work Pins in place and ready to weld Drilled a hole for a 3/4'' uniseal and shoved some 1/2'' fittings in there for water in Bought some 1/2'' spa flex and layed out 5 segments Cut 4 slots Set up a test Water on Not to sure I like this. Will try plan B tomorrow.

05/26/2012, 11:46 AM	#21
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	Thanks 1221, Well plan B was a bust!!!! I thinks I am on to something withthe Loc-line. Plan B-1a, up next

05/27/2012, 10:36 AM	#22
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	Here is plan B-1a, LOL I like the flow pattern of this plan, it will also be very easy to adjust. I drilled holes in the loc-line. just a twist here and there wil direct the flow toward the center. The pump is a mag 5 @ 500gph

05/27/2012, 11:02 AM	#23
feruz Registered Member Join Date: Jan 2011 Location: kuala lumpur,malaysia Posts: 18	great work...

05/29/2012, 02:51 PM	#24
wastedtime Registered Member Join Date: Jan 2012 Location: Massachusetts Posts: 72	If I were you I would just keep it in the backyard as a nice water feature. Looks great.

05/29/2012, 07:24 PM	#25
peppie Registered Member Join Date: Oct 2009 Posts: 1,775	I am not sure the wife likes the upsidedown plastic thing look for a fountain. LOL Did a little work today on the cup neck. The twist lock approach was what I chose to use. It is simple to make and it will be easy on easy off.