Advice before printing AIO insert for 40 Breeder (IM15 Upgrade)

[ShaunMc]

Hey all,

I wanted to check with the group on any lessons learned or advice for building a custom AIO (All-In-One) insert for a 40 Breeder tank.

I'm planning to move everything over from my Innovative Marine 15 and wanted to recreate a similar AIO experience inside the 40B — just on a larger scale. I've designed the insert to drop in and convert the tank into a peninsula-style layout. I've triple-checked everything from dimensions, flow paths, and equipment fitment. I’m comfortable with the overall design and flow planning, but this is my first time printing and assembling something this big.

The insert is 441mm wide, so I'm printing it in two parts, which will then be bonded together. I'm leaning toward using Weld-On 16 or Loctite Marine Epoxy to join the two halves — but I’d really appreciate any tips on:

• Bonding large PETG parts reliably
• Surface prep or finishing for saltwater safety
• Any structural reinforcements people found helpful
• Mistakes you made (so I can avoid them )

Thanks in advance — I’ve seen a few of you pull off some awesome AIO builds and would love to learn from your experience before I fire off the final print!

 

[mpatterson42]

Don't just glue two flat parts together, it won't hold that well. What I do is print holes where the two parts will meet and then I print something just a little bit smaller that will fit into these holes so it has a mechanical connection.

 

[ShaunMc]

Don't just glue two flat parts together, it won't hold that well. What I do is print holes where the two parts will meet and then I print something just a little bit smaller that will fit into these holes so it has a mechanical connection.

Got it. I can add some pegs. Thanks.



updated: 4mmx12mm so the front is still flat, but these will go through the back, into the left and 2.5mm into the front. thanks for the advice. @mpatterson42