OldSchool 225 build with some new twists.

[OldSchool Reefer]

LOOK AT THAT BEAUTY!!

Really enjoyed following along with the stand building/staining and truly it looks amazing. The tank is beautiful and I think it makes that space that much more amazing! Keep us updated for sure, and I would second any @reefnutrition product I love them!

Thanks! It’s probably my last tank and I wanted it to be a nice big one! Lots of work crammed into a short period of time! It WILL get better so stick around! I’m already making big changes to the plan.

 

[OldSchool Reefer]

The backside frame finished supports for the beer ledge biscuit joints glued and it’s all glued and screwed down. The doors are trimmed to fit so it’s time to test fit the granite!

 

[OldSchool Reefer]

Hard days work this weekend I got a lot done but not as much as I had hoped. I wanted to get some water in it but just couldn’t swing it. Happy it’s Monday :/ so I can check on the sump parts and get some Granite epoxy. Funny how things work out there is a Granite place right next to the shop CNCing my parts! Back home by noon to do my first ever granite install! Granite went smoothly but cleanup of the silicone off the acrylic took a while but by 10 I’m getting some RO/DI in the tank!

 

[OldSchool Reefer]

I made 50 gallons of RO/DI last night, and will make another 50 tonight. Going to add 2 bags of Reef Crystals with a Tunze Stream and I should have 100 gallons of good usable water in the tank in the morning. Should have rock going in by the weekend.

One big Tunze rocking the full length..... we have Saltwater! This called for the Beer ledge to be christened!

 

[OldSchool Reefer]

As planned I had 100 gallons of 1.026 saltwater this morning. Giving it a few hours to clear up a bit more before I start loading rock. Opened up a new pair of MP 40s to add some more flow before I add rock. As soon as I got all firmware updated and linked to Mobius and was happy with my level of knowledge of this New technology and about to move some rock the phone rings.

I was Shocked, my sump parts were ready for pickup.
So I Jump in the truck and head out, I honestly didn’t expect them till Friday so I was unprepared.

Checking fit and prepping to glue it up!

This is going to take a while!

 

[OldSchool Reefer]

Not a lot to report today, things are still moving forward. It’s been Two days of water in the tank and it’s still a little cloudy. I’m used to Reef Crystals leaving chalk in the mixing barrel but this time it’s all staying in suspension, so I added a few pieces of live rock to kick things off. I’m thinking with a little bacterial biofilm coating everything most of this should fall out of suspension!
Work on prepping the sump for partitions is progressing but it’s a slow process. It’s not the first Acrylic tank I have polished but hopefully the last! The tank had travertine tile on the 2 none viewing sides so the crazing there and where some large cut limestone blocks sat was minimal, but other places it was pretty bad especially under the deepest parts of the sand bed. And to make things worse all the fine crazing cracks had calcium deposits. This will not make for good solvent adhesion of the partitions so it has to go! This will take Hours of wet sanding with citric acid water followed by buffing before I can glue it all up. Then there is the corner of the overflow where they added some gusseting that has to go!

 

[OldSchool Reefer]

If I was more prepared I could be working on plumbing now. Well that’s water under the bridge! Spent most of the morning cleaning up the sump where the partitions go, and removing the remainder of the gussets at the corner of the overflow box. Lots of grinding and wet sanding, some with an orbital sander and and some with a good old block and elbow grease. Started with 320 grit dry on the real bad spots then wet sanded with 600, 800, 1000, 1500, 2000, and finished with 3000. I think I can skip arms for a few days from that workout!

 

[OldSchool Reefer]

I always knew that the most challenging aspect of this Tank to sump conversion was going to be the corner overflow box.
There are several problems ahead besides the obvious holes in the bottom that have to be filled. The corner was bent instead of using 2 pieces and having a square corner with a seam. The joint there will have to be reinforced and liberal use of thick cement. The other problem is the size is just wrong The outside dimensions of the overflow are 12 X 6 I need an inside Dimension of 7 X 6.5 for the Klir 7 Looks like this box will have to grow some.
I decided to finish cutting and fitting partitions because thinking thinking of growing that box was hurting my brain and the Adult beverages weren’t helping, so let’s use a saw instead!

 

[OldSchool Reefer]

While I have a minute let’s talk about Acrylic. Sheet Acrylic is a cast material and thicknesses vary if you are buying 3/8 or 1/2 inch remember it’s not! That being said about now my perfect dimensions aren’t so perfect and the drawings are for reference only! It’s cut test fit trim and fit from here on out!
I feel Old acrylic had better quality control on thickness and tends to be closer to 3/8 or 1/2. If it’s old enough It can and will craze with the paper on and you probably can’t get the paper off unless you use some industrial grade GooGone.

Now that the glue remover has set for a few minutes it’s time to clean up the mess and get on to the next cut.

 

[OldSchool Reefer]

Works like a charm! A little soap and water and then citric acid and it’s ready to install.

 

[OldSchool Reefer]

Wouldn’t you know it the smallest partition that never made it into the plans would be key in setting this sump build. I always knew that I needed a baffle in the rock section to direct the flow and separate the inlet side from the skimmer from the outlet to the fuge but just thought I could add it anywhere in the process Nope the hole thing depended on it hanging out holding things up! This is the only baffle where the top edge isn’t hidden by the sump top so I had to give it a nice smooth edge. Cleaned it sanded it test fit it and cleaned it again before removing the rest of the parts so I can get it into place glued down on one side before moving on to the rest. I got everything squared up and ran some Weldon 3 down the edges and gave it a rest!

 

[OldSchool Reefer]

This is taking forever! Everything needs bracing, or spacer blocks and a few clamps. My table saw is getting a workout! I’m having to build this thing one compartment at a time. I had to build the skimmer platform braces before I could finish closing in the corner of the overflow and put the sides in. :mad:

Now it’s ready for a side but first I have to cut some spacer blocks to keep everything square!
I flipped it back on its bottom to allow some gravity to lend a hand.

while I’m here I might as well cut some egg crate for the skimmer platform.

 

[OldSchool Reefer]

Egg crate? Where did that name come from? We have been using it forever in reefing and always called it that but does anyone else? If you go to one of the Big Box stores and ask for some Egg Crate, they will give you that look, you know the one. Anyway all the new light defused at the Box stores is real thin not the thick stuff we used to get. My neighbor who is a great guy (I wish all the neighbors were like him) is in the drop ceiling business, so I told him what I was doing and asked him what happened to the thick light defuser. He said what? I haven’t seen any thick Egg Crate in many years! ;Facepalm The next day there was a case of Egg Crate on my porch. It’s a good thing because I’ve broken several already so I’m doubling it up!

Did you ever notice that those squares aren’t square? I cut three trying to get get a pair to match up it’s a good thing I have plenty! There is no telling how many I’ll go through doing the 20 X 30 frag section .

 

[OldSchool Reefer]

Well I’ve decided! Old School wins the egg crate cutting debate! After almost a whole day of nothing but sump platforms with egg crate tops the side cutters and belt sander combination win hands down! The cut bracing blocks and glue up 2 pieces Sucked for an idea, still had to clean it up with the belt sander and orbital sander!

Sure it’s strong but not worth the effort!

If you don’t take my advice here please at least take the paper off before making those tiny spacer blocks! ;Facepalm
Things went much smoother for the frag and reactor compartments with the side cutters and sander!

It all fits! Huge sigh of relief!

 

[OldSchool Reefer]

Test fitting of components continue now with the top on. It wouldn’t be the first time I built a skimmer stand or platform for something only to find out it didn’t fit or it had to go in at an angle and the diagonal was longer than the side :mad: everting fits through the openings as it should! I was mostly concerned with the Tunze Skimmer and it’s funny outlet pipe with post filter carbon sock. I really liked the idea that whenever I ran Ozone that water would pass through carbon.

The Carbon and GFO Reactors Will take some creative plumbing when that time comes but I’m still uncertain of where to run the outlets. The easiest place would be the Fuge but they will probably interfere with the light.

 

[OldSchool Reefer]

Since I took the skimmer out of the Big Rock tank ( yes the Big tote has all the Big Rocks) I should move the rock into the house. These rocks weigh between 50 and 70 pounds I have always had help when ever I moved them before but none is available so I’m solo on this. I never had a tank so big and tall that a small step or milk crate didn’t give me the access I needed. I had to step up the game for this one and buy a work platform for this operation. First the Big rock goes in a tote on a wheelie cart wheeled into the house placed on a piece of starboard on the platform. Then I put another piece of starboard on top of the tank I step up onto the platform and lift the rock onto the top of the tank. I take a deep breath and pickup and lower that heavy thing into the tank;Dead

These Big rocks are kinda special to me they were cut from prehistoric reefs while making canals in south Florida and the keys.

 

[OldSchool Reefer]

With most of the rock from the totes in the tank ( I haven’t looked in the old sump yet ) I started looking at the Klir 7 compartment. I spent the cooler hours of the morning fixing some of the worst glue joints in reefing history and it just got too dang hot to sit outside and do serious thinking.

Thats a full 7/8 inch I have to grow this chamber. Not to mention it has to be dropped about 4 inches!

 

[OldSchool Reefer]

Growing the Big one continues! Besides wet sanding and buffing not much left to do before I do the final cutdown. This overflow box has been nothing but trouble the quality of acrylic for one anything I have used to cut it has gummed up no matter the speed and sure enough when I went to cut it down to grow the chamber it cracked. Not really a show stopper but another thing to work around! First I added a 1/2 inch layer then a 3/8 to finish it off. It will be capped with a piece of 1/2 inch white. Support for the Klir cut and the vertical.

I need 1.5 inches but shooting for 2 inches before the overflow from the compartment.

After lots of grinding filing and sanding the extension I think it’s getting close to done. Started trimming the 1/8 inch stock to fit and though I should check orientation and clearance that pipe is really close and I have a motor to contend with. Yup it won’t go that way so I turned it 180° yup it fits but there is a nylon screw on the bottom of the Klir and part of the filter sock adapter plate that I must accommodate. :mad:

Well that was easy the screw head is accommodated but the adapter plate is going to be a PTA so I dig out the router attachment for the Dremel tool. I think I have used EVERY power tool I own on this sump build!
Before I can proceed with the fleece roller aspect of this compartment I have to plug those holes! I spent the better part of yesterday cleaning up the bottom around those holes. The amount of glue down there was unbelievable!

So first I find some scrap acrylic with a thickness close to that of the bottom. Remember I said this material is cast and thickness varies! Lots of work on the belt sander and it’s a good fit. The bottom plate is all trimmed and sanded but how do I hold it all together? Glue will be everywhere and I could end up gluing something to the bottom of my sump if I don’t figure this out! Electrical tape should do the trick and any seepage can be sanded off. Taped the plugs in and glued it all up. After about an hour I filled the bottom with glue ( Weldon 16 thinned 10% with Weldon 3) I dropped in the new bottom and
Got busy clamping!

It will sit until morning but this is probably my best glue joint of the whole project and it needed to be!

 

[OldSchool Reefer]

I ran out of Weldon 3 if I can’t find any locally today I know what I’ll be doing! This isn’t my first time so I know how bad it will suck, at least I’ll be outside making a mess

 

[OldSchool Reefer]

I found some Weldon 3 this morning, so I got a reprieve from wet sanding and buffing! Tomorrow is supposed to be great weather, perfect for that dirty job!
Lots of cut, fit, cut, fit, sand (I got pretty proficient at Dremel routering and plunge cutting with a table saw ) going on here but it’s all coming together perfectly! I’m having a cocktail!

It’s fitting like a champ so I’m doing a little happy dance as I’m shaking up a batch of Margiretias!

We came in right at 2 inches so I’m making it a double!