Kput's plywood 400 build - Home for my sweet baby Cowfish

kput

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Hello all!

I entered the reef scene here about 6 months ago, and tend to go a bit overboard, so here we go!
I currently have a 120 gallon mixed reef, I purchased the tank used back in January, and reused the sand, rock, etc. so the tank is faily well established. After having the tank for a while, I've become quite frustrated with several aspects of the tank, and I'm ready for a change. My centerpiece is a Longhorn Cowfish, who is about 5" long right now. I purchased him for the 120 with the intention of building him a bigger home as he grew.

The current tank has numerous scratches on the front glass.. This makes cleaning it a pain in the ****. I've also got a good amount of vermitid snails trying to take over that I haven't been able to get under control, and the cabinet is also stuffed full with an oversized sump, I barely had room for a 5g ATO resivoir, so it's time for a change before I rip my own hair out.

I plan on taking my time, and doing everything the right way. I will be bringing in a carpenter friend to assist with the tank build, a plumber friend to make sure the plumbing is right, and an aquascape guy, because I'm terrible at all of those things LOL. The only equipment I plan on carrying over from the old tank will be the dry-sides of my MP40's for additional powerheads in the new tank. I'm not going to risk bringing over any of the dang vermitids, and will part the old tank out.

And so it begins! Once the tank is built, I will have to move the 120 over about 6' to accomodate the 8' tanks permanant home. Not looking forward to the move, but hopefully I can get it done pretty easily.

The tank;
Dimensions - 96x36x30h - (Internal dimensions 94.5x36x28.5). Should give me roughly 400 gallons once the pond armor and glass is in place.
Glass - 1/2 annealed, standard glass (I'd love to go low iron, but I can't find anyone locally that supplies it, and just don't want to spend 400$ for shipping)
Stand - 32" high, two doors in front, control board cabinet on the side, open back

I plan on mostly following DIYKing's build, however I've read through almost every Plywood build thread on the internet I could find. I plan on using 3" wide, 3/4" plywood all the way around for the bracing. 3/4" Birch for the tank, coated deck screws, and Pond Armor for the coating with fiberglass seams. I can't find 3/4" or 5/8" glass locally, so I will be using 1/2. I know that 1/2 inch is technically only rated for tanks up to 27" high, but the way I'm designing the lid, I will have a water level of approximately 27.5" so I think the 1/2 should suffice. It will give me a safety factor of like 2.76. I will have 3 braces going vertically across each side, and 9 braces on the rear. I am not 100% decided on the top yet, but it will either be 3, 3" braces, or 4 2" braces. I think I'd prefer the 2" to help keep shadows at bay. I considered doing glass like AlexG, but I plan on running glass lids, and just couldn't think of a feasible way to make it work.


Lights - Radion
Powerheads - MP60's / MP40's
Sump - ???, possibly considering a trigger systems sump, I'm undecided. I want a seperate section for filter cups similar to the Emerald I use on my 180 FW.
Overflow - ???, been trying to figure out what to do here. I really wanted internal overflows, but it doesn't seem feasible. External overflows won't necessarily work either, due to the plywood framing around the top of the tank. I'm trying to get my hands on the overflow skimmers Sealthbox uses on their system.

I plan on running a full set of reactors, and any auto dosers I might need and will have it all set up before the tank runs, just so I don't have to plan for expansion. I will run an AquaUV sterilizer, not sure on size yet.

Photos show my current 120, as well as taped off lines of how the 400 will fit. I was a bit concerned with the width, as it sticks out further than the dividng wall, but I plan on getting rid of the air hockey table, and I honestly think it'll be just fine.
More photos to come as I get everything ironed out and start building!! Any tips would be great.

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ca1ore

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Use the same approach for the overflow acrylic tank builders use - a cutout over the skim box. Or go with Modular Marine who make a removable skim box.
 
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kput

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Use the same approach for the overflow acrylic tank builders use - a cutout over the skim box. Or go with Modular Marine who make a removable skim box.

I looked quite a bit at the modular overflow boxes.. Unfortunately due to the bracing in the back of the tank (4"x3/4") at the top of the tank, it wouldn't be possible to install the box flush / properly at the back of the tank at the water level area. I reached out to customaquariums, and I think I'm going to pick up 3 of their surface skimmer overflow heads, and just drill a hole, mount the bulkhead, then I can customize my water level as needed with the skimmer pieces. Not really what I wanted to do, but honestly I think it'll be fine. I'll do a durso style drain on the back of the tank to quiet it down a bit, and will probably do 3 1.5" drains (middle, far left, far right).


 
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ca1ore

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Buddy of mine had those for a while .... hated them. Just buy the internal skim box and attach that to your three dursos.
 

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What was his issue with them?

They are ugly and don't work all that well - not enough linear overflow length.
 
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kput

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They are ugly and don't work all that well - not enough linear overflow length.

Hmm, thanks for that info. I'll take into consideration!



Still working on planning out the blueprints with my carpenter friend. The tank itself is designed and ready to start purchasing supplies, we're now moving onto the stand. The stand will be a bit more complicated as I need to fit as large a sump as possible, a big ATO, and I'm really wanting a giant fuge so I can run a variety of Macro, and house a Mantis shrimp of some sort.

I'll also need an electronics board/cabinet, space for a calcium reactor, algae scrubber, KH Guardian, and a co2 tank. It's going to be a tight fit.. I've got a preliminary quote and ideas from Advanced Acrylics - 48x24x15 sump, 24x24x20 fuge, and 8x24x20 ATO. This gives me 15 gallons of volume in the ATO, and 45 gallons on the fuge.
 
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kput

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Not much to update at this time, I'm wating for the final plans to come back so I can start buying wood and getting this thing built.
I've decided on a few things, the biggest issue has been figuring out the biggest sump I can fit down below, while also having a fuge, ATO, and all my other accessories below the tank. I've reached out to almost all the custom sump builders around, and surprisingly enough a lot of them aren't making sumps any more. I really liked a design Geo's Reef had available, but he didn't really want to do the custom sizing and such I was wanting. I think I've decided on an advanced acrylics sump finally.
I'll be going with 72x22x16. The first Chamber will be drains, spilling into filter cups, followed by a large skimmer section, return section, and lastly a giant fuge. The fuge will be designed so it gets a lower amount of flow, and will also be blocked off so I can house a mantis shrimp in there and he can't get into the other parts of the sump for a while. I've wanted a mantis for a while, but haven't been too excited about setting up an independant system for him so this will be perfect.
Ideally I'll have all the probe holders, two heater holders, etc. all built in. Will also throw in an 8x22x? ATO res and still have about 10" of room horizontally in the stand for a controller cabinet.

22" depth on the sump will give me enough room for a large calc reactor up front, and the KH Guardian will go mounted on the sides. The large fuge will also be perfect for the scrubber to sit without making the sump area seem crowded. I've decided on red accents, as I plan on running Reef Octopus reactors/skimmer. I think red and white plumbing will look nice :)
 
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kput

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My carpenter buddy has been working diligently on the design of the tank, and has some mostly-final renders done. We had to do some slight adjustments to the front, just because we can't get plywood in lengths over 96", but here's what things should look like..
The program he uses will allow us to map out the cuts on each board, so we aren't wasting plywood and can maximize the wasted wood.

We are planning on using the pocket hole jig on all the vertical supports to connect them with the top and bottom horizontal bracing, rather than just to the tank wall. Hopefully this gives us a little better support all the way around. Braces will be spaced 4 7/8" apart, which gives me room to mount my Vortech MP60's in between where needed.

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kput

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Making SOME progress on this build..
My entire house needs re-floored, as my pets have ruined the carpet. This includes the room that my current 120, and 180 gallon tanks reside, as well as where my 400 will be going to replace the 120.

I decided that before I throw a 5000lbs tank down, I should go ahead and take care of the flooring. I've spent the last 3 weeks ripping out carpet, tile, etc. to try and get the house ready for the guy to come in and drop flooring down for me.

I'm on bare slab currently, and with the large tank going in I decided I should go ahead and add some more power, to replace the currently overloaded 15a circuit this tank is on. I cut channels in my slab to run two new 20a GFCI circuits, electrician came in yesterday and got everything ready for me. Conduit and wire is run.

I've decided to also go ahead and add a 1/2 PVC water line in the channel, with an access panel by where the 400 will be. I will move my RO and mixing station downstairs, and run the line to the station so now I don't have to run 50' of tubing across the house to add RO, etc. I will also add in a 1/4" RO line, with the hopes of automating a pump to fill up my RO res in the future. I will finish up the plumbing tomorrow and get everything moved downstairs. Will update once I figure out how to plumb everything in the wall.

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kput

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So after quite a bit of deliberation, I think I've decided to go with a traditional glass tank on this build.. I really wanted the size of the 400, but after labor, etc. was all added up, it would have been around $1500 for the tank. I can get a planet aquarium 310 for around $2700 delivered, with a crystal front, overflow, etc. This will give me a full viewing area, and more peace of mind from catastrophic leakage.

I'll, sadly, have to start a new build thread in the smaller tank build page :'( so much for my dreams of a monster tank LOL.
Fortunately, the 300 will be plenty big for a fully grown cowfish, with plenty of room for other tank inhabitants. The 400, while nice for the extra size, will be more expensive to maintain, and doesn't really add a lot of room for additional livestock comparatively.
 

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