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Old 06-28-2009, 09:59 PM   #1
Staplesofficewar
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Staples 46 Gal Bowfront Build


Alright, I figured it was time to get serious about this whole posting thing. I will do my best to give more regular updates. Anyways, since the other build thread had an odd title, I decided to open this one with a consolidated picture show. For anyone who wants to see the original thread it is here.

Here is the tank when I picked it up in Atlanta: Nasty!



The First step...Let's get some holes drilled. But wait, this has a tempered bottom! So.....what to do...let's see....How bout we replace the whole bottom?! Yea, that will show them all.

Remove it first (the bottom):







Pick up the new drilled bottom at the Glass shop:



Mask the glass to make the new Silicon Nice!



Drop a bead of silicon around the edge and place the bottom. Use a nice amount of weight.....allow to cure.
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Old 06-28-2009, 10:05 PM   #2
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Next, I built an overflow box from 1/4" Black Acrylic. Installed and held in place with the bulkheads.




Install the return and the drain inside the box. You'll see soon that I choose a different method later...

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Old 06-28-2009, 10:10 PM   #3
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Stand time!


Ok, now next I built the stand.

First, gather the needed equipment.

I think it's all there.


Next, cut out the top and bottom of the stand. The dog keeps everything in check.



Remove some mass from the top of the tank. This is the piece that the tank will physically set on.



Make it taller:



Does it fit on top?

Yes it does.



Install the front oak panel - notice the sound deadening insulation on the sides. the stant has this between all the external and internal walls:



All sides installed - door rough-cut and edges (two front ones) prepared for edging using a router:

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Old 06-28-2009, 10:11 PM   #4
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From the front:


Lets start on the canopy:



the tank - on top of the canopy:



And finally the last pic of the post and also as far as I have gotten - installing some oak on the canopy:



If you couldn't tell, I like wood glue - it's fantastically stong and wont rust. If anyone has any questions, thoughts, concerns, please chime in.
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Old 06-28-2009, 10:18 PM   #5
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Made up some doors - which do not hinge. They are held on by magnets, but I wanted to make sure I had
lots of elbow room.

Here the stand and canopy are with the oak trim resting on top. I had to order it from the north. No one here in Augusta stocked it!













Then I got Married! and went to the Riveria Maya in Mexico...Don't worry, we missed the Flu.






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Old 06-28-2009, 10:25 PM   #6
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Ahhh Cancun....seeing this pictures again makes me wanna get my passport back out and hit the tarmac!

Me and the gf...err ....I mean wife:






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Old 06-28-2009, 10:26 PM   #7
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OK, All sanded and ready to be stained:

Pre-stain Pics:





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Old 06-28-2009, 10:27 PM   #8
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Stain it!




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Old 06-28-2009, 10:28 PM   #9
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Poly Coat it!

Theres 2 finished pics:



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Old 06-28-2009, 10:33 PM   #10
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Got the skimmer...and we have a problem.....Skimmers don't work well in fresh water. Here it with fresh water in it.....and here is where I became a little smarter regarding that fact.



Ahhh....with some salt water...


I have started modding this skimmer to make it more efficient.
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Old 06-28-2009, 10:34 PM   #11
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I decided, due to the shear amount of noise generated from the water fall coming down the pipes, to go with a siphon drain system with 2 drains.

What are the disadvantages of this design?

What are the advantages, besides a completely silent tank?

I understand that there are other ways to make a tank less loud, however, I am willing to bet there is no other way to make a tank much quieter then this. I tried the Durso, etc this time as well as with my last tank, and even though I could get the top quiet, the bottom was like a hot tub. Anyways, here are some pics.


Here is the tank from the front. This is without the top installed. With the top on, the return (shown at the top of the picture) will go through the back and into the water.





This is the return from the side. The black bulkhead is where it plumbing will tie into the canopy.




Looking into the sump. Top Center of the door you can see the drains. The one on the left is the primary, the one on the right is the emergency drain.




Better view of the drains. The one with the gate valve is the primary drain.





Here is the input to the refugium. It comes from a tee that connects it to the main drain. THere is a gate valve to slow the flow in the refug waaaaay down.




Here are the two drains. It's hard to tell, but the primary drain (on the left) is about 3 inches lower then the emergency drain (on the right).




All these images are shown with the ViaAqua 3600 running unrestricted except for the elbows, tee, pipe length and head. My last test calculated the flow at a little more then 600 GPH.
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Old 06-28-2009, 10:43 PM   #12
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OK, this weekend I worked on the control system for the system. Here is a pic of the 2 micro PLC controllors and relays.





Made some fan mounts and created the cover for the exhaust holes.





That's it for this edition. Ordering lights next weekend!

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Old 06-29-2009, 12:09 AM   #13
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..........and this thread has officially started to blow my mind. one of the cleanest set ups from scratch ive seen.
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Old 06-29-2009, 07:13 AM   #14
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Thank you Much
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Old 06-29-2009, 08:31 AM   #15
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Yes what a great job making it and pic!
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