Bioload 75 - Reef Aquarium

[bioload]

I did several passed and was not very pleased with the results. It appears that every time I rotated the tube in the jig I did not get it back the right position for the next pass. The pic below shows the edges of each cut which did not line up properly.



I decided to remove the jig and use the guide alone. The guide was clamped to the edge of the table and while pulling the tube against the guide made several more cuts.



The results were better this time around. However, I does take some getting used to working with such a large peice. There were several cuts where my hands shook a bit moving off the guide and the following notch created by the router bit meant I needed to make a few more cuts all the way around.

[bioload]

After going around a few times I finally got a cut that I was pleased with and should make for a good clean bond.

[bioload]

More Pics.....

This is what I'll be using for the union between the skimmer body and the collection cup. I've used several times in the past but this time I will make some more modifications.



One good thing about using the cleanout is availabiltiy. You can pretty much find them in any hardware store in sizes which include 2", 3" amd what I'm using the 4"

The downside I found in my previous skimmer was the number of turns required to get the collection cup off. This time I'll try to make a lower profile union and will use a PVC cleanout instead of the ABS below

[bioload]

The first mod is to remove the square in the center of the plug. I've tried several methods and I've found the easiest way is using a hole saw on a drill press. The one below was done with a hole was that was too small. I then proceeded to cut the remaining bits off with the mitre saw, but I wouldn't recommend it.....you can see the damage to the plug cause be the saw which will preven a good seal later on.



Once the center is removed it's off to the router table to clean ot the rest of the material with a flush trim bit. Care is needed when doing this to prevent the peice from being pulled out of your hands and trown across the room. A jig can be used, but I find if you exert enough downward elbow grease I'm okay.

Always take note of the direction of the router bit and make sure you start the router givving enough time for it to come up to speed before putting the peice in position........and watch your fingers



When completed you should have a piece that looks like this....and if you're Canadian....the double/double should be there as well

[bioload]

As I mentioned before the number of turns required to remove the collection cup was somewhat annoying at times. It did not required a lot of height to be removed but I'll try another mod this time by shaving down the threads. This was done once again on the router table with the bearing removed from the flush trim bit. You can also use a straight bit but I was too lazy to swap it out.

I placed the piece against the fence of the router table (turn on the router first!!), and made light cuts rotating the piece each time adjusting the fence.

Setting the fence for the initial cut



Finished piece. I had to keep checking the threads on the cleanout to ensure that I didn't take too much off. When I was done there was less than a 1/4 turn in order to connect the two pieces, and get a tight fit with the gasket....forgot to mention that the plugs also come with a gasket.



This completes one half of the union/flange that will be attached to the top of the skimmer body.

[bioload]

The cleanout was simple cut on the miter saw leaving only the tread portion. I could have made the cut thinner but would like to keep all my fingers.



Once that was done I followed the same process as I did for the plug using the router. Before I could do that though I needed to get rid of those little "bumps" on the side. If I didn't I would not be able to rotate the piece on edge. I adjusted the fence to the right distance, and rotated across the bit.



and here is the completed flange/union....which is it by the way?

[bioload]

Here is a shot of the body about to be solvent welded. Nothing special....just place it on the sheet and weld.



Almost forgot.....I usually add some weight before gluing....oops "welding". Paint cans come in handy. P.S. I use Benjamin Moore.....no matter what the guys at HD say .....This was some of the cheap stuff the builder left behind.



Excuse my foam job on the door in the background....that stuff goes a long way!

Off to the router table again. After about an hour or so I cut out the tube making sure I put the bearing back on the flush bit.....it's so easy to forget. I usually place masking tape on the tube if it didn't come with any protective film, which all of the ones I've ever receive didn't have.