LFS sump design! Help me brainstorm?

UncommonSense

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So, my LFS has two identical 60” x 18” x 16”T, 1/4” thick rimless acrylic sumps for their identical dual single-drain overflow 180g rimmed glass tanks. They are very old-school, and gave me creative freedom to update their filtration to the 21st century!

Both are the LFS owners personal tanks, one is a soft coral dominated reef, the other is a planted freshwater display. I’m replacing all four bulkheads on both tanks while doing these sumps; converting from dual Duroso to dual Herbie drains on both tanks, with returns plumbed up the back/over the rear rim of each tank!

These sumps are just acrylic boxes, no internal baffles or anything fancy… they’re both quite old, I’d guess at least two decades… hilariously; constructed of yellow acrylic less viewing pane, and not very well to boot!

The top opening of both sumps appears to have been cut larger at some point in history by Stevie Wonder himself! — I immediately pulled my router out to fix that…

Note the concerning lack of center braces; which I do plan to reinstall!

In any case: I plan to add acrylic seam reinforcements to every single seam of both sumps, followed by 1-2 top center braces each, and all the associated sump baffles…

Here are my questions:

1: what bubble trap design does everyone prefer? One weir and two “down baffles”? Or one “down baffle” and two equal height weirs? — I’ve seen it done both ways, the former seems more logical; is it just preference?

2: I’ve crudely sketched up four sump layouts; there are obviously plenty more… These are my general ideas for skimmer placement, return pump chamber size/placement, refugium placement, and drain placement… — keeping in mind that my LFS likes large sump chambers to work in, and the FW sump should have a large center display refugium; which of the four proposed sump layouts would you go with? Or, which alterations would you make?

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TX_REEF

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neat project. I generally prefer bubble traps like this because it creates more surface movement preventing formation of bio-film:

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UncommonSense

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neat project. I generally prefer bubble traps like this because it creates more surface movement preventing formation of bio-film:

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That makes perfect sense!! I’m imagining that it will be less useful downstream of the skimmer chamber though…

What about a conventional single weir bubble trap just for the return pump chamber (best bubble trap performance), then a double weir bubble trap (best surface skimming of bio-film) for every compartment prior?
 
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I threw a few hours at it after work… all structural parts are 3/8” thick acrylic at dead minimum….

I spoke with my LFS owners, regarding my sketches. They liked the idea of a right to left configuration, simply for filtration efficiency… the protein skimmer chamber was omitted in favor of a massive 32” long, 17.5” wide, 12” water height refugium chamber, with the skimmer sitting on a 4” tall stand within! — this will yield more space to culture live rock within the system!

I opted for only one bubble trap; prior to a 20” long return chamber section (old school, no ATO!), and a simple filter sock holding weir in the drain compartment!

I’ll finish thorough weld/silicone prep, cut my two filter sock holes in the heat bent drain compartment acrylic, then make it all one piece tomorrow!

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I like the protein skimmer chamber to be fed by a surface skim and the exit to not be a surface skim so the gunk builds up with the skimmer to be removed. But I could be wrong.

Neat stuff, you work very fast.
Thanks for sharing.
 
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I like the protein skimmer chamber to be fed by a surface skim and the exit to not be a surface skim so the gunk builds up with the skimmer to be removed. But I could be wrong.

Neat stuff, you work very fast.
Thanks for sharing.
Haha why thank you! It helps to have the right tools, materials on hand, and a month of talking about it behind me!

I considered this, actually! Here’s my preliminary sketch to help you visualize how the surface skim passes though the refugium, where the skimmer will be located! Then, water exits via the bottom of the refugium to the bubble trap, then return pump chamber!
(Ignore the middle baffles I scribbled out; I opted to omit them)

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neato! that old acrylic is a real trip 😆 they're lucky to have a DIY warrior like you around
Haha right?? These are the only yellow acrylic tanks of any kind I’ve ever seen… the 90’s were weird…

Thanks! I’ve definitely spent the past six months really heavily investing my free time in an intensive self-education on glass, and acrylic fabrication, on top of several decades of DIY experience! — I’ve actually got plans in the works to fully reinforce a rimless glass tanks seams using interior glass reinforcements, cut in a similar way!
 
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Another busy day… I only managed to get around two hours into the acrylic work today; I decided to cut two 6.625” holes for filter socks, and router finish all exposed baffle/brace edges with a radius bit… the former ate up most of my time, as my biggest hole saw is 5.5”…

So, I ended up drilling multiple smaller holes for each large filter sock hole, then die grinding to my final diameter, before beveling the radius of each hole via router… (both sides of each hole; I don’t like any exposed sharp edges in anything I make!)

Sadly, no silicone/welding today, I need the sun to dry the sump, and all my parts after a thorough soapy water scrub and RO water rinse to guarantee good weld strength and silicone adhesion!

Here’s progress…

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I also ended up edge finishing the scrap cut out from the hole which obviously took me way more time; it came out looking too interesting to just throw away! —
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I finished up all 15 siliconed parts last night; it was a LOT for one person!!

staying ahead of skinning silicone to lay all reinforcements and baffles, (13 parts) made it quite rushed!

when I do the second one, I’m definitely going to have a helper on hand to either lay the silicone, or wipe fillets in the beads/pull masking… it was too much to do cleanly alone at my skill level!

(Thankfully, my LFS cares a WAY more about function than form in this ancient sump, and this will DEFINITELY function!)

Here’s the finished product, less welded top braces I’ve been procrastinating on! — pressure test is next Thursday through Saturday; then installation!


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Bulkheads, and filter socks are in!

Surprisingly, I nailed the filter sock hole diameter; despite not actually having any 7” plastic ring socks around to test fit! — The plastic rings are a snap-in fit to the holes! (Thanks to those of you who updated the filter sock hole size thread!)

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Well, it’s ugly, but it holds water like a champ now! — this is the most water this sumps seen in at least a decade and a half!

I’ll let it sit full to the rim until at least Saturday, then bring it in to my LFS to install it!

i also got a few hours of plumbing done for the upgrade; return plumbing up the back of both 180g tanks, plus a majority of the eight drain subassemblies!

I’ll be starting on an identical sump for the FW display next…

— does anyone have any suggestions for the freshwater sump design? I planned to make it identical, minus one bubble trap “down” baffle (return chamber side baffle)… I’ll also likely add some form of sliding grate to the bottom of the remaining “down” baffle in the refugium, allowing my LFS to use that chamber for something besides plants… Beyond that though; I haven’t gotten too creative with it!

Thoughts? Suggestions? Questions? — Input is always appreciated!

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Installation day!

Pressure testing is complete, the tank is solid and no longer leaks!

Maximum vertical pane deflection is just shy of 6mm; well within acceptable tolerances!

I’ve already got 70-80% of the plumbing subassemblies all glued up… I just need to do the last three return plumbing fittings, replace the four tank bulkheads, and glue up four drain subassemblies during the sump swap!

— The plan is to shut down/drain the identical clone to this sump which is currently under my LFS’s 180g reef tank. From there, we can disconnect plumbing/electrical, and slide the existing sump out of the stand… then, I can go in and do bulkheads, before we slide the modified sump into place… then, plumb drain and return lines, reinstall equipment, and refill!


after the sump swap/plumbing upgrade, I’ll be bringing home the identical sump we pulled out, and proceeding to repeat the process, modify it very similarly to the first one; serving as their 180g freshwater display’s sump!

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Success!

It took around 5 hrs of consistent work; but the sump is installed under the 180g at my LFS, and circulating water!

All four drain bulkheads were replaced, drains plumbed, returns plumbed, etc!

I didn’t have a chance to get much in the way of photos among the flurry of activity, but plan to go back tomorrow for final touches, such as standpipe mufflers!

Next up; 180g DT freshwater sump design!

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I sketched up a quick scale diagram of the 180g freshwater system’s proposed sump design last night; baffle fabrication will happen this evening with any luck!

The design is nearly identical to the saltwater sump, less a bubble trap baffle… the idea being to have a “display refugium” under the 180g DT, effectively serving as a bonus tank for my LFS!

Thoughts? Questions? Constructive criticisms? — I’m open to suggestions for design revisions!

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the last of the acrylic fabrication is all finished up; I forgot to make the top braces yesterday, and still wanted to clean up the ugly top rim/sand sharp edges…

With any luck, I’ll find some time tomorrow to get all parts prepped, and final clean the sump itself… I may or may not get into actually putting the thing together until this weekend!

There’s still time if anyone has any bright ideas for design revisions?

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Success!

All acrylic seam reinforcement and both weirs are siliconed in! — this time it went MUCH more smoothly, despite not having any help again… (Practice makes perfect!)

I just need to silicone in the filter sock holder, the “down” baffle in the refuge, and slides/retention for the livestock containment grate (parts which don’t silicone in contact with any “old” silicone)! Oh, and weld on the top braces…

I’ll likely see about getting more Weldon this weekend so I can have this sump curing all of next week!

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Sliding grate is built!

It I actually took less than 30 mins from layout to finished/deburred, 1/8” polycarbonate, 17.375” X 6”, 3/16” holes on a 1/4” grid.

I’ll probably weld an acrylic “knob” onto one face with Weldon #16, Just for style points!

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