DIY Tips: Modern acrylic fabrication and techniques.

Treehrtsme

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Rumors going around Weldon is soon to be illegal so I suppose that will be another major topic here....


Been wanting to start a thread on this topic for some time but the actual interest seems to be on and off. With the thread competition going figured I'd contribute to the community a little. In more recent years we've been seeing some interesting stuff on the market like this guy

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Naturally the price tag is what we DIY in part to avoid. With CNC and laser cutters becoming obtainable or more accessible I've been working with the industrial art program at a local university to get behind whether building a high end sump with the bells and whistles is something that's worth investing time into. I've also been doing work with various other engineered plastics to see the practicality ofmaterials aside from acrylic and glass in the hobby. One project I am to start soon is taking to aquaforest 980s that were thoroughly destroyed in transit and trying to salvage the pieces create one functioning song. These particular sumps are full PVC and as such this will be an interesting project, shout out to Reynolds advanced materials for helping me source weld on 40 local.

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I have a few years of experience with acrylic fabrication and have been particularly interested in what and how some of the bigger names in the custom gear game have been doing. I've seen a lot of broken equipment in my time gotten a good idea of how different companies do things different ways and hope to share my opinions and experiences moving forward.

We already have some great guides and resources on this site from people much more experienced and seasoned than myself, but here I'm going to try to focus on current popular trends. I have full intentions of running an afr in my reef octo sumps. Anyway I'll update as I progress.

Things I hope to cover in more detail include working with PVC and acrylic, bonding acrylic face to face, going over some past projects I've done and complications I came across. I recently gained access to some more industrial equipment including a full size CNC mill so projects I've set aside due to the amount of time it would take for me to make all the cuts by hand or something that I can potentially mess around with and give a go.

*** Got a personal request from someone. I'm the past I have fit AFRs in sumps they had no place fitting. And these situations I personally like to use a clarissea but if you're working with something with a 7-in filter sock chamber brief mat isn't out of the question. I'll see if I can pull up some pictures from a mod I did a couple years back that's not something I would do again. Sk-5000 in a e shops af-100. At the simplest of levels you'll see how much I had to trim away from the rim of the sump just to fit it in and without the use of an extension arm in the inlet going straight into the AFR it would not have been possible. This is an extreme scenario. For anyone with a 7 inch filter sock, this modification would be just a matter of patience and some careful work with a dremel. I also had to trim away from the room a little to fit an oversized skimmer cup. In the case of a 7-in filter sock, simply turning the circle into a square will do it for you most of the time regardless of the roller though a 1200 likely would be too large. I mainly used circular sanding bits twitching between grit and occasionally using a diamond bit as I went through a good number of them. In the end the filter sock holder which is actually proprietary in this sump had to be almost completely trimmed away.

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Not to mention the nylon screws to be flattened out as I was using a version 2.
 
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JTP424

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Syringes (the actual needle kind) were a lifesaver for me regarding applying solvent. Helps with control and easy to apply via wicking.
 

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I wasnt sure what you meant to do with the broken aquaforest 980s sump - but generally acrylic and pvc dont bond well. i am sure you are aware of it. Here in UK we use Tensol 12 for glueing acrylic.
 

Troylee

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Repairs are easy! Wanting to build a custom one with all the bells and whistles is a waste of time and money! I’ve built a few hundred sumps and the best ones are just wide open with a bubble trap for the return pump! Don’t limit yourself with stuff that you don’t need down the road! Simple is better and the options are endless that way! If you make built in reactors and a fuge etc it’s all wasted space you’ll wish you had back!
 
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Treehrtsme

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Syringes (the actual needle kind) were a lifesaver for me regarding applying solvent. Helps with control and easy to apply via wicking.
I was in medical school for some time and it was essentially given a massive bag of syringes for various purposes. I found that my personal favorite became a TB syringe, 3 ml, with a high gauge blunt tip needle, I want to say something like 28 or 29 gauge. The applicator bottles honestly held way too much and were occasionally hard to control
 
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Treehrtsme

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Repairs are easy! Wanting to build a custom one with all the bells and whistles is a waste of time and money! I’ve built a few hundred sumps and the best ones are just wide open with a bubble trap for the return pump! Don’t limit yourself with stuff that you don’t need down the road! Simple is better and the options are endless that way! If you make built in reactors and a fuge etc it’s all wasted space you’ll wish you had back!

Don't disagree at all, though I recently had someone ask me a good way to swap out a permanently a fixed 7 inch filter sock for a reef mat 500. Well this could be a simple job you could also make modular plates to fit different Rollers and even put back in the sock. A couple of nylons screws and some proper cuts and you have the option to upgrade your own gear. This thread is a bit for the gear junkies among Us and for me to document some of my projects and failures. Perhaps at the end of all this I'll come to the same exact conclusion, that all of it was ultimately a waste of time.
 
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Treehrtsme

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Wear a proper respirator & cartridges to protect yourself from these solvents!

Dog Heart Sunglasses GIF by MOODMAN
:smiling-face-with-sunglasses:

I find that some of the PVC solvents in particular can get nasty the rest assured I do work with a respirator if not in a very well vented area
 

Troylee

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He is easily my standard for getting started on acrylic and I cannot recommend his articles highly enough

Ummmm yeah… if you haven’t noticed they went mia! I wouldn’t follow anything they say lol! Ive been doing custom acrylic work way longer than that place ever stayed in business lol.. the owner was telling people to silicone the diy kits they offered lol lol!
 
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Treehrtsme

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Ummmm yeah… if you haven’t noticed they went mia! I wouldn’t follow anything they say lol! Ive been doing custom acrylic work way longer than that place ever stayed in business lol.. the owner was telling people to silicone the diy kits they offered lol lol!
And to be honest I did say that as a bit of a formality. Tbh regardless, the diy acrylic guide is a bit aged and the popularity of acrylic especially in the home hobby scene has only increased over the years. Don't believe those techniques or methods are set in stone either.

Aside from the hopefully well known "silicone just doesn't chemically adhere to acrylic" any modern tips you'd like to throw out? Honestly writing this whole thing I came to debating writing some things that are almost like trade secrets but at the end of the day I'm likely just taking things too seriously.
 

Troylee

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And to be honest I did say that as a bit of a formality. Tbh regardless, the diy acrylic guide is a bit aged and the popularity of acrylic especially in the home hobby scene has only increased over the years. Don't believe those techniques or methods are set in stone either.

Aside from the hopefully well known "silicone just doesn't chemically adhere to acrylic" any modern tips you'd like to throw out? Honestly writing this whole thing I came to debating writing some things that are almost like trade secrets but at the end of the day I'm likely just taking things too seriously.
Not really any trade secrets! It takes patience and practice… everything you ever wanted to know about acrylic is in this diy forum between myself, turbo aquatics and others.. it’s about to change as methylene chloride is being banned! There won’t be any more Weldon 3,4 channel bond etc.. lots of us make our own solvents with Mc and acetic acid etc.. I’m not sure what the industry is gonna do even as the acrylic monomers such as Weldon 40,42 will be affected by the new laws going into effect.
 
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Treehrtsme

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Not really any trade secrets! It takes patience and practice… everything you ever wanted to know about acrylic is in this diy forum between myself, turbo aquatics and others.. it’s about to change as methylene chloride is being banned! There won’t be any more Weldon 3,4 channel bond etc.. lots of us make our own solvents with Mc and acetic acid etc.. I’m not sure what the industry is gonna do even as the acrylic monomers such as Weldon 40,42 will be affected by the new laws going into effect.


I'll have to ask my chemist his thoughts that's news to me. That could be a chance to make some money. Until then better stock up. I've messed around with alternatives to no real avail
 
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Treehrtsme

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I'm gonna through out this one: I have some half finished sump build that are waiting on an afr to be implemented much in the same manner geo does. Looking for a solid file for CNC or laser cutting that would simply product a grate (perhapsb hexagonal the style plate to act as as grate to make the area larger. I'll have to see what it can find
 
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