Through Wall 200 Gallon Construction Project

[ReefTankENG]

04/2024: Time to move the old tank to clear the way. I plan to move everything from the old tank to the new tank when the time comes. But for now, I just need it out of the way
Current set-up

Drained the tank as much as possible to make it easier to push to the new location

New spot next to my "way easier" and "less interesting", planted tank

And the wall is free for destruction!

 

[Joe Glass Cages]

04/2024: Time to move the old tank to clear the way. I plan to move everything from the old tank to the new tank when the time comes. But for now, I just need it out of the way
Current set-up

Drained the tank as much as possible to make it easier to push to the new location

New spot next to my "way easier" and "less interesting", planted tank

And the wall is free for destruction!

Looks like a Glass Cages Classic. that is from some time ago. Awesome. Watching your journey. Thanks so much for the support too

 

[rayadog]

Was your wall wider or thinner than the tank? How old is the house? Just curious. Trying to distract my jealousy as I have a 55 and of course this is what I’d rather have.

Our house is older so we have uninsulated plaster interior walls. So I’m wondering if theres anything of note for this tank or adjoined rooms in the colder or hotter months?

 

[ReefTankENG]

Looks like a Glass Cages Classic. that is from some time ago. Awesome. Watching your journey. Thanks so much for the support too

Haha, yeah I bought that in 2014 with the stand. A guy drove it down to Florida and we made the swap at a gas station! And everything lasted great - that’s why I stuck with Glass Cages for this tank!

 

[ReefTankENG]

Was your wall wider or thinner than the tank? How old is the house? Just curious. Trying to distract my jealousy as I have a 55 and of course this is what I’d rather have.

Our house is older so we have uninsulated plaster interior walls. So I’m wondering if theres anything of note for this tank or adjoined rooms in the colder or hotter months?

The house was built in 2009. The wall was just drywall and 2x4s (my next posts will show the demolition). We live in north Florida so the temperature swings are nothing significant, so I don’t really have issues there.

 

[rayadog]

Nice! couldn’t be “simpler”

 

[ReefTankENG]

04/2024: Taking down the drywall. I made sue this wall was not a structural wall (did that before starting anything). But I also wanted to reinforce things in the attic before doing anything. I put plastic over the room opening and the went-to-town. I'm not sure if I mentioned this, but I tried to keep as much of the drywall as possible on the opposite side of the wall.
Built this to help reinforce the part of the wall that will be remaining.

Glued and screwed it to the top of the wall in the attic

Prepped the room

Tool it all down!

Karate chopping the last piece of drywall, one of the rusty nails got me. Needed a tetanus shot

I hadn't really put much thought into the electrical. But now it was staring me in the face...

 

[ReefTankENG]

04/2024: Electrical and reinforcement. I had two breakers feeding this wall. The main one dedicated to the room was going to power the Apex and most of the stuff. I also had a breaker that was connected to the refrigerator, so that one was going to be for lights and a few other things that did not need Apex.
My electrical plan

Starting with some new boxes

Added some 2X4 anchors for the support beam and some box cut-outs for the electrical boxes

Starting to wire them up

Completed the electrical

Added the support beam

Next up, remove the studs!

 

[ReefTankENG]

05/2024: Stud removal time. One of the main challenges was trying to save the drywall on the opposite side of this room. A carbide reciprocating blade and magnet to find the screws did the job.
I first removed the furthest studs to assess the stability of the drywall.

As you could imagine, it was quite flimsy. So, I added some 1/2" plywood to stabilize it before removing the center studs.

Also, the 1/2" plywood will serve as the back mount for anything I need to hang.

Made a cut-out to see what the wall had in store for me for routing my supply and drain line for the sink. The wall by the sink is an outside wall.

Added the same 1/2" plywood to the other side

Also added an extra piece above the support beam for a little extra section modulus. And this would be the back of my "hood" - yet to be designed.

Now for the scary part - removing the final studs... nothing moved, everything felt very stable and secure

A bunch more wood filler and sanding

And the final paint job

Next is to bring in the stand!

 

[ReefTankENG]

05/024: Brought in the stand. Centered and test fit with the challenge of leveling.
She fits pretty good

Making sure the sink fits. Tight fit!

So I left the bottom 2X4 on the wall because it was too hard to remove and I needed it to keep the other side of the drywall. I knew I was going to have to figure a way to level the stand. So I cut a bunch of "shims" of different thicknesses from 2X2 stock to get a level plane. I glued them to the 2X4 to form a level surface for the stand on the backwall.

Next I had to level the front of the stand. I level the front corners and cut a bunch of different thickness "blocks to fit tight under the leveled stand. I must have went back and forth like a hundred timed to my chop saw to get the perfect fit for each of the pieces.

All-in-all I had about 50 2X2 shims through the grain to support the stand. It always shocked me when I see videos of people leveling their tank stands with a few shims in the corners... what's supporting the center from bending? I guess it works, I wasn't taking any chances.

I cut a small square through the drywall as a preview for what was to come

From the other side

Next up is to finish cutting the through hole and building the picture frame...

 

[ReefTankENG]

06/2024: Making the through wall opening!
I cut this with a razor blade to reduce dust. It took forever, I probably would use a reciprocating saw if I had to do it again.

Then I build a frame to smooth out the cut drywall

Installed it and "mudded" it in.

Began pictureframe installation

Lots of wood filler and sanding between the picture frame and drywall frame to make it look like one piece

All together and sanded.

Painted... looks like one piece

From the other side

Next is for the tank!!!

 

[ReefTankENG]

06/2024 Tank Install. It finally arrives. Glass Cages Aquarium. Rented a U-haul to pick it up at the freight center and said a prayer to hope it fit! The stand is 42" tall with a 2.5" lip to get over. I had the manpower to lift it, but I was concerned about the height and getting it over that lip.
So I rented two of these things to make it go smooth

Out of the truck

Getting ready for the lift

Getting it on the stand

It fit!

Other side

Next is plumbing

 

[Gumbies R Us]

06/2024 Tank Install. It finally arrives. Glass Cages Aquarium. Rented a U-haul to pick it up at the freight center and said a prayer to hope it fit! The stand is 42" tall with a 2.5" lip to get over. I had the manpower to lift it, but I was concerned about the height and getting it over that lip.
So I rented two of these things to make it go smooth

Out of the truck

Getting ready for the lift

Getting it on the stand

It fit!

Other side

Next is plumbing

Good luck with the plumbing! That tank looks great right there!

 

[Joe Glass Cages]

Following!!!! What a great build thread. Love watching your journey come all together @Gumbies R Us

 

[ReefTankENG]

06/2024: Outdoor plumbing: Part of this whole project was to get me out of the laundry room. So, I needed a sink to get me through water make-up, water changes, and cleaning. I plumbed a sink next to the fish tank.
I was pulling water from an outside spicket, no hot water

Needed a helper to handle the drainage pipes

Digging was by far the worst part. All the roots and getting the slope correct. Cutting into the main sewage pipe also had a "pleasant" smell - wasn't as bad as I would have through, but still nasty

Running the drainage line from the sewage pipe

Going around the corner, under the landscape wall

Final pipe run into the house from the drainage line to the cold-water supply line

Going into the house.... pretty intimidating cutting holes through the exterior wall

Hooking up the interior sink. With an additional attachment for RODI

Working pretty good!

 

[ReefTankENG]

Following!!!! What a great build thread. Love watching your journey come all together @Gumbies R Us

Thanks!... and thanks for the great tank!

 

[smitten with ocean life]

this looks fantastic!!

 

[ReefTankENG]

07/2024: Overflow plumbing fit. I wanted things to look professional, so I painted all my PVC plumbing.
Dry fit for the overflow

Piping painted... you will notice I forgot to put on the threaded collar, that sucked when I realized it. I went with a ball valve instead of gate valve because of the extra space the gate valve would have taken.

Everything painted and will sit around until ready to install

 

[ReefTankENG]

07/2024: Adding the side frames. Basic 2X4 assembly to create the outside cabinet look.
On this side I had to modify the 2X4 to account for the overflow.

Secured both sides in-place to the previously installed 3/4" plywood on the sides

Added 1/2" plywood on top to finish it off

 

[ReefTankENG]

07/2024: Hood Frame. This build was pretty straight forward. Just matched a frame to the design and everthing that was already build.
Lots of clamps and gorilla glue

Test fit with some trim molding