DIY ROCK RETURN COLUMN:
Pt1.
At first I tried this with the plans off a You Tube Tutorial. That does not work for returns!!! Too heavy on the bulkheads.
Here is a of pic of what NOT TO DO.
I wound up scrapping this column due to weight mainly. This being said I will show you how to do this right.
For the column jig:
You will need a tall enough piece of 6" (1/3 the height of your return) pvc, a length of 3/4" pvc a table saw with a thin cutting blade on it a 3" pvc pipe the height of the return a pvc toilet seating ring, pvc primer and glue, duct tape and plastic wrap.
NOTE: You may have to go to a plumbing supply place for 6" pipe and if you will be doing overflows also count that in too. Be warned... Most plumbing suppliers only sell it in 10' and 20' foot lengths ask if they have scraps.
Cut long ways the 3/4" pipe down the center to make 2 halves then cut to 2" longer than the 6" pipe section. Use the purple pvc cleaner for the edges of the 3/4" halves and the inside of the 6" tube. Cut the 6" tube exactly in half. Then glue the halves down starting at the very edge. This takes time! You have to hold each piece or two until set. You do not want them to come loose.
Put the finished halves together and Duct tape snugly on one seam. Add a length of duct tape to one side of the other.
Cut about 3 pieces of plastic food wrap twice as long as your jig. Set aside. place the toilet seating and 3" pipe together and stand on a covered flat surface.
On the inside of the jig lay out the plastic wrap so it hangs over both openings and covers all the pipe. This can be a little frustrating. Painters tape to temporarily hold to the outside is ok.
Now place the jig over the pipe and toilet seating. Adjust to be sure you have even spacing between all the way around.