I just picked up the materials to start on this build for Potroast. 

• 40g frag tank
• 1/2" walls, 3/8" top & bottom
• Internal 1/4" black coast-to-coast overflow which will also have an adjustable fence (not shown) that will give the option of operating the overflow as a weir or with slots/teeth
• External 3/8" overflow box with 3 bulkheads for configuring just about any type of overflow system (including the "BeanAnimal Silent and Failsafe" system)
• Back, sides, and bottom will be skinned with black vinyl (a LOT cheaper than black acrylic, and looks the same)
• Lids
• Stand-offs for egg crate (either built-in or free-standing)

But enough talk...pictures!





Clear View



Overflow box (with Bean system sketched in)



Side View



The internal box will probably be 1" lower to allow access to it, since the adjustable fence can be raised to achieve the desired water level.

I've always rattle canned the back of my tanks, looks absolutely perfect. Is that advised against? I guess I would expect to see differences in vinyl adhesion pressure and and small bubbles trapped under the vinyl unless it's flawless.

According to Jason (kirklinsclownfish) it comes out perfect. He has a technique he was telling me about that takes care of the bubbles issue. It isn't a stick-on vinyl like window tinting, according to Gary (gcsoupman) that doesn't work because acrylic off-gases and you end up with bubbles. I can't see how the two would be different, but I guess they are. So that will be an interesting part of the project.

Cool, cant wait to see how it comes out. As you know...I'm working on a project and I'm always open to new ideas!

One thing after another and enough delays already! Here's a few pics!

Sides and back with pass-thru holes routed



Sides bonded to back



Tomorrow the front goes on, 24hrs waiting then a flush trim pass, then over the weekend the top euro and the internal overflow, the bottom and the external overflow early next week. The tricky one will be designing and fabricating the internal overflow as it will be height-adjustable and have a weir on one side and a teeth on the other so you can flip it over.

Front on

Well I was going to post a few pictures, then realized that I forgot to d/l them off my camera. So all I have is a cell phone pic of half the euro top cutout done.



Got the other half done right after taking this pic so that's done now. I also have the internal overflow box done and ready to bond, which I will be doing today sometime (maybe on my lunch break) so that I can put the top on tomorrow. I'll have the external box done over the weekend and bond that in place early next week.

The internal overflow box is pretty cool - I'll be posting many pics of it when it's finished!

Looking good! Can I place my order now?

If you can wait a few months, I'm pretty backed up! I have it on good authority that there will be another acrylic shop going up in Des Moines very soon though

More progress, and more pictures!

Better pic of the euro



Internal overflow done and bonded in place.  It has tapped holes for thumbscrews (which are on order) and will have a front cover (yet to make)





euro set on top of tank (not bonded)



Sides and back of external overflow bonded



Bottom marked up for holes



I drilled the holes smaller with a hole saw, then used a template and the router to finish them off for a perfect hole. Here's 2 done and the template.



All done, BRS-80 1" bulkhead fits perfect!



The top joint is too long to do by myself, so I was going to have Mike help me but the weather was not too cooperative today in Des Moines. Oh well.

Only thing left to make is the front cover of the internal overflow box. I have a slot template, but it's not exactly perfect, so I'm going to re-make it tomorrow. Hopefully the weather will be on our side tomorrow and we can get the top put on.

Got the top joint done yesterday afternoon and it turned out fantastic! Also got the bottom panel bonded on the overflow box, and started work on building a new and better template for routing teeth. Of course, I forgot to d/l the pics again. Bottom will go on Tuesday.

Overflow box, need to rip off the excess on the back edge, then flush trim the bottom, round the edges, and that's done



Top euro pinned and shimmed





Ran the joint (thx MJB for the help), pulled the pins, then all hail Diet Barq's, the one with BITE



Yeah!



Sexy



Tomorrow: bottom
Thursday/Friday: flush trim all around, round edges, start polishing, bond external box, finish overflow fence

You said it, sexy. That's a very good looking frag tank and I like the reversible front cover on the internal overflow...pure genius. You'll have to take some good pics of that and show it off. Could be a popular option!

I'm gonna steal one of those diet barqs next time I'm over...getting tired of the taunting >:-(

Bottom on



and I still have all my Diet Barqs HAHA! Mike forgot to steal one.

Posted By Floyd R...Turbo's Aquatics! on 02/08/2012 09:54 PM
Bottom on



and I still have all my Diet Barqs HAHA! Mike forgot to steal one.

Actually I was going to pop a box open and take one but I didn't want to risk shifting the tank on the fresh joint!! 

There was a cold 12 pack in the fridge. Bummer for you.

Flush trim done, corner round around the top, euro, and vertical edges done!





And the OVERFLOW FENCE is finally done! Knocked it out tonight

Here is the permanent part



This is the fence



Here it is with teeth up at max height



lowered



Weir up





Lowered



External overflow box shown where it will go and will get bonded on after polishing

looks real good

REALLY GOOD!! ;=0)

Definitely a work of art!