300 Gallon Sump Conversion

Finally got my router table finished



and got to work on the first project. Matt Nelson (ninjazx777) tore down his 300 and needed it turned into a sump. It will have an intake section with transition to a filter sock holder for 3 7" socks, then a large frag tank section, a dual anemone tank, skimmer section, and return section. flow through the sump/tank will be roughly 10,000 GPH.


For baffles, we're using the old busted up sump that was behind Seascapes' big tank when it blew. We've been working on this on and off all week. I will tell you right now that the only other time I will cut up an old tank and make baffles is the old cracked tank from Grove & Platt. After that, never again. It's a total pain, because the material is warped and encrusted. Good thing I have plenty of Lemon Pledge to slick up the router table!!


300G on left, busted sump on right



To make the baffles, I cut up the sump with a circular saw, then we squared and trimmed the pieces on the table saw, and did final trim and edge prep on the router table. Still picking acrylic shavings out of my hair from the circular saw part.



Sealed holes in the bottom of the overflow



Got a few more holes to seal



The bottom of the 300 was warped outward when not under pressure, so to get it flat to bond the baffles to the bottom, I needed to improvise. I folded up a long piece of cardboard and stuck it underneath, then put 4 buckets of rock on the top, then a 2x4 piece of MDF leftover from the router table...



...then finally found a use for the old G&P tank - layed it on top of the MDF after running the Weld-On #4 into the joint!  This pic is after I took it off.  You'll just have to believe me that the MDF and tank were on those buckets.



Did the same thing for the last baffle this morning before heading off to work.
That's where it stands for right now. Between tonight and tomorrow, Matt and I should be able to finish this bad boy up!

 

We finished it up on Saturday.

Holes sealed up



Here's the filter sock holder, partially set in place



Here's Matt cutting the overflow teeth. Notice the proper use of the guard.



This is the baffle that separates the frag tank from the dual-anemone tank



which got #5 mesh plastic canvas attached w/epoxy



Anemone tank section (not done)



Had to put the tank on end to bond parts of the filter sock holder and anemone tank divider



Quality engineering at work. This held one seam in place so we could flip the tank to bond a couple final pieces



Done!



Intake section, Filter sock holder, up/downs, and probe holder



Dual anemone tank, skimmer chamber, outflow chamber



We barely fit it into the minivan



what's left of Seascape's old busted sump

 

Thank you for all the help! My wife wouldn't have the garage back yet without it, and I would be in the doghouse. I also now know that the maximum capacity of our minivan is. And what not to do on a router table. Along with many other things!