Some more work on the tank. Since I've finally installed the sump I need an overflow box in the main tank to replace the plugs installed when the tank was filled
I was able to get an off cut from Piedmont Plastics for approx $5.00 sq/ft including taxes. Have quite a bit extra that I can use later on for the media reactors and skimmer. First step was to rip a 6" wide strip for the overflow.
Using the table saw again cut the pieces for the front, back and side of the overflow. The box will measure 6"x6"x4"
Once the cuts were made with the table saw. I then set up a straight edge on the router table to clean up the edges that will be welded. I just use a simple level for this clamped to the table. I don't have a jointer at the moment, but this works fine.
The guide was set to just shave the edge of the piece. Important to do one pass per piece before moving the guide to ensure all the pieces have the right dimensions. Top of each peice then bottom, then sides etc.
Here is a look between the edge from the table saw and after routing.
Once the edges are cleaned up with the router I usually do a dry fit to ensure everything lines up right.
Before welding the pieces together I marked where the bulkhead would be installed on the box and drilled a hole using a hole saw. Just placed is on the back of the tank which was drained and traced the hole.
I used a standard squeeze applicator and Weld-On 4 for the solvent. Both can be obtained from Piedmont Plastics. I would recommend practicing on a scraps if possible to get used to the applicator. When inverted the solvent flows very fast. Squeezing the bottle before inverting helps control the flow, but takes some practice to get right
When bonding two pieces I leave a slight edge that can be cleaned up using the router table afterward.
Once the front, back, and sides are all welded, next step is to clean up the edges.
Attaching everything to the bottom. This piece I did not cut on the table saw. I simply glued the box onto the oversize bottom and again passed on the router
Completed box
I had some egg-crate that fit nicely into the top of the overflow to prevent anything from going into the drain
Finally installed the box into the tank. Ensure that the gaskets are in the right spots.
Flange -> Gasket -> Overflow -> Gasket -> Tank -> Gasket (optional) -> Nut
HTH,
Sunil