Saltwater mixing station trouble shooting

Kyle Seeley · Mar 28, 2017

Hi all! I've been working hard lately and finally got a saltwater mixing station all hooked up and looking exactly how I would like! Depressing part is that once I got RO flowing into it the bulkheads developed a leak. Is it possible over-tightening, not getting a clean cut, or just low quality bulk heads could cause this? The bulkheads are at the bottom since everything is gravity fed so they are on a flat surface... any info helps! Even just the basics on how to install one! Thanks!!

cshplumber · Mar 28, 2017

Interesting set-up. Can't see leaking bulkhead in pic but a common mistake is that rubber washer needs to go against the bulkhead not the nut.

Kyle Seeley · Mar 28, 2017

Yes the washer is against the bulkhead side. I'm wondering if not getting a clean cut hole could have messed with the seal?

cshplumber · Mar 28, 2017

Doesn't need to be round. Just needs to be surrounded by gasket with no burrs to inhibit proper seal. Could also be thinner plastic of trash can warping when filled with water.
I silicone all my bulkheads on acrylic but would probably try an epoxy on that one.

spieszak · Mar 28, 2017

I'd kill the bulkhead and use a uni-seal

Kyle Seeley · Mar 28, 2017

Will the uni-seal work on flat surface like that?

spieszak · Mar 28, 2017

Its not flat, thats the point.

cilyjr · Mar 29, 2017

The bottom where he drilled the bulkhead likely is flat. I'm assuming you didn't drill right into the ribs/bumps that brute cans gave ringing the bottom. If you did.....start over...

But yes a uniseal would work. That said you already have holes for bulkheads. A uniseal would likely require a smaller hole.

My guess would be it's not seated properly. Meaning the hole had some junk around it, or the gasket is improperly placed, or its too tight/not tight enough.
You can tighten a little more with the plastic brute can then you would with glass (not too tight to compress and misshape the rubber gasket) I usually give them 1 more turn when mounting on thin walled hdpe.

spieszak · Mar 29, 2017

cilyjr said:
The bottom where he drilled the bulkhead likely is flat. I'm assuming you didn't drill right into the ribs/bumps that brute cans gave ringing the bottom. If you did.....start over....

Your right, I'm so used to seeing people drill through the side that I didn't even notice it was the bottom. My bad

don_chuwish · Mar 30, 2017

As with anything, take it apart and see! Probably debris preventing a good seat.
Also, about that stand - it looks beafy with all those 4x4s and 2x4s, but all the water weight is on the screws holding the platforms to the 4x4s. Add some 2x4 'jack' studs under the first platform going to ground, then again from the first platform to the bottom of the 2nd. One at each corner. It is attached to the wall right?

Kyle Seeley · Mar 30, 2017

Thanks for all the replies!

@don_chuwish, I completely agree with you. I am taking apart this weekend to check on the seal. Also I will take your advice on the jack studs. That should sturdy it up even more! And yes, it is attached to the wall.

@cilyjr, I did drill on the flattest part of the brute. I am going to try reseating the bulk head this weekend. But if it continues to leak I will try and switch to a uniseal. According to marine depot the holesaw size is the same for both fittings!

Overall though what do you guys think? Is the design pretty practical? Didn't have the money to do all of the fancy pumping some others are doing. First time attempting something like this!

don_chuwish · Mar 30, 2017

Overall I think it's fine. Can you gravity feed new salt water to the tank or is it bucket work? Adding a pump in future would be simple enough. I went vertical on mine too for the sake of footprint and using gravity. I can run a hose to the ATO reservoir to refill it with gravity alone.

Kyle Seeley · Mar 30, 2017

It is bucket work! I just wanted something neater than what I had going on up in the attic. Tank is too far away to be able to do anything like that!

Brew12 · Mar 30, 2017

Was I supposed to be looking at something other than the box of roman candles?

cilyjr · Apr 2, 2017

@Kyle Seeley did you get it to stop?

Your design will work it's not dissimilar to what I have.

Kyle Seeley · Apr 2, 2017

Yes sir! Just got everything going! I ended up cutting the pipes so that I could get to the bulk heads. I re cut the hole with a 1 3/4 in. hole saw, sanded the edges and made sure that there was no debris blocking the seal. I then did a bead of silicone along the inside and outside of the bulk head. Test filled everything with tap water and no leaks! Starting to fill with RO as we speak!

cilyjr · Apr 2, 2017

Right on. The silicone was probably overkill. But whatever it works so it's a win.

Side note. Did you wait a few days before filling after the silicone? Most silicone likes a good few days to become fully cured (and inert).