DIY PVC and Acrylic Sump

[allen00se]

Hello Reefers,
I am planning to build my own sump and figured I could document it here for all to see. I am still in the design phase (Fusion 360) but plan to pick up my material and begin cutting soon. My tank is a 5 foot long 150 gallon from SCA, which means I have a about 55"x 22" of free space inside my stand to work with. As of now I plan to make the sump 40" long, 20" deep and 18" tall.
The majority of the sump will be made from .5" thick white PVC, the rest will be viewing windows made from .25" thick acrylic. This is somewhat for design aesthetics, but also because the PVC is much cheaper and easier to work with.

I have a CNC machine in my garage which I will use to do the cutting of the PVC and Acrylic.

Here are some images to give an idea of my plan.

And here is my Tank Build Thread Build Thread

 

[Dom]

Why not make it completely clear? Aren't you concerned that the cutouts for the "viewing windows" only add to potential leaks?

 

[Sean Clark]

So when can I put my order in? lol

 

[allen00se]

Why not make it completely clear? Aren't you concerned that the cutouts for the "viewing windows" only add to potential leaks?

It has to do with the bonding strength of PVC to acrylic. I have seen others that make the whole front panel out of one piece of acrylic, but I don't trust the method of gluing a sheet of acrylic to the edge of PVC. Once my design is complete you will be able to see that each window will sit in a pocket of PVC and any water pressure will just push the Acrylic into the PVC pocket. Also all of the PVC will be slotted together.

 

[MoKan Reefer]

Hey @allen00se I'm actually not far from you (just up 44 in Joplin), definitely going to follow this.

 

[allen00se]

Hot off the press, cutting the rest as I post.

 

[allen00se]

should get the acrylic pieces for the windows cut tomorrow, just have to decide what glue to use. Weld-On 40 is what’s recommended to bond the acrylic to PVC but no one around here sells it so I might try some other options.

 

[allen00se]

glueing in the front acrylic viewing panes.

 

[flagg37]

Definitely following along. I’ve thought about doing this for a long time. I’ve done full acrylic sumps but never worked with PVC. What will you be using to bond the corners (pvc to pvc)?

 

[allen00se]

Definitely following along. I’ve thought about doing this for a long time. I’ve done full acrylic sumps but never worked with PVC. What will you be using to bond the corners (pvc to pvc)?

Weld-On 16
I’ve used it many times in the past on this sheet pvc, but this is the first time I’m doing anything water tight, so I hope it works. I’m planning to do a filet on the inside corners with silicone or something of that nature to make double sure it doesn’t leak.

 

[Lost in the Sauce]

Weld-On 16
I’ve used it many times in the past on this sheet pvc, but this is the first time I’m doing anything water tight, so I hope it works. I’m planning to do a filet on the inside corners with silicone or something of that nature to make double sure it doesn’t leak.

The cnc cut rabet in the pvc, with your acrylic nested in should be completely water right. WO16 will fuse them creating the water seal.

 

[flagg37]

I’m totally trying this now. When I researched it before, the person was using a special tool that heated and welded these PVC rods. I wasn’t convinced that I wanted to buy another tool for one project.

 

[allen00se]

Added a silicone bead to the back of the viewing panes for an extra seal. I made sure to cut them small enough to have a gap around the edges for the silicone to squeeze into.

just need to glue the face on and do a leak test now.

 

[allen00se]

Yay, it didn’t explode when filled! Even better is that so far I only see 1 pinhole drip coming from one corner.

 

[Lost in the Sauce]

Looks pretty fantastic.

 

[flagg37]

So how much does a sheet of 1/2” white pvc go for these days?

 

[allen00se]

So how much does a sheet of 1/2” white pvc go for these days?

~ $100

 

[Rjramos]

Yay, it didn’t explode when filled! Even better is that so far I only see 1 pinhole drip coming from one corner.

Looks like the leak is pvc to pvc. Nothing around the acrylic windows? That’s where my concern would be. Disimular plastics don’t bond well together. Hope the silicone works especially with that rabbet cut into the pvc. Flexing, due to water pressure might cause separation with time. I am following because I make acrylic sumps. Another thing, don’t know if you looked into a 1/2” white acrylic sheet and cost as compared to PVC sheet.
This would solve your bonding issue.
I believe the PVC flexes more although it is easier to cut.

 

[flagg37]

Yay, it didn’t explode when filled! Even better is that so far I only see 1 pinhole drip coming from one corner.

Do you have any idea why it leaked? Like do you recall not putting as much Weldon on in that area or something? Did you do the silicone in the corners? Would you do anything differently looking back?

 

[Rjramos]

Looks like the leak is pvc to pvc. Nothing around the acrylic windows? That’s where my concern would be. Disimular plastics don’t bond well together. Hope the silicone works especially with that rabbet cut into the pvc. Flexing, due to water pressure might cause separation with time. I am following because I make acrylic sumps. Another thing, don’t know if you looked into a 1/2” white acrylic sheet and cost as compared to PVC sheet.
This would solve your bonding issue.
I believe the PVC flexes more although it is easier to cut.

I looked it up on eplastics. Black or white acrylic is crazy expensive comparatively! 3/8” and 1/2”.