505g plywood build Qs

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Crispy

Crispy

Fire Eel
MFK Member
Jan 11, 2009
1,213
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Ontario Canada
So I'm getting the plans together to build a 9'x3'x30" plywood tank. I have 7'x2' pane of 1/2" glass for the viewing window and some other 2'x2' panes of glass for side windows. The DIY threads are amazing, but I have a few Qs....

1- I don't see many DIY tanks with the side panes, but there are a few. Is it a huge hassle to install side panes?

2- I'm thinking of going with zavlar since it's cheap and available in my area, anything I should know about using this product?

3- I can't find much info about installing bulkheads for my overflow, I assume I can drill them out and silicone them in?

4- with a 7' viewing window, do I need to brace it in the middle?

thanks in advance MFK experts.. the DIY section here is second to none!! ;)
 
1- I don't see many DIY tanks with the side panes, but there are a few. Is it a huge hassle to install side panes?
Do the side viewing windows just like you would do the front window. I would frame them seperatly instead of having the 2 windows meet.

2- I'm thinking of going with zavlar since it's cheap and available in my area, anything I should know about using this product?

It is a great product but it might not get along well with silicone. I used the US version made by the same company and silicone did not stick to it and it did not even cure over silicone. I had to use fiberglass resin on my viewing window frame to get a seal, but that another story. I hear that 3M 5200 might bond with it.

3- I can't find much info about installing bulkheads for my overflow, I assume I can drill them out and silicone them in?

Bulkhead fitting are a breeze, probobly the easiest part of the entire build. No silicone required, get fittings with gaskets. Go to flexpvc.com for fittings.

4- with a 7' viewing window, do I need to brace it in the middle?
No, not with 1/2 glass!
 
thanks ross! just the answers I was looking for... still debating what I'm I'm gonna use to waterproof it, zavlar looked cheap enuff and is available in my area.. hmmm...
 
If you go with that, do some testing before you start messing with the viewing window. I used the US version (pond coat) made by Permadri and had a problem with the viewing window. Silicone did not stick to the liquid rubber. And LR over silicone would not even dry. I ended up having to apply fiberglass resin to the area where my window was going to be and extended that about 2" into the tank. I then siliconed the window to the resin. After that was dry, I applied the LR over the resin that I extended into the tank right up to the silicone sealing my window. There was a build on here recently where 3M 5200 was used and it sealed to the LR. I might order a tube just to do some testing myself.
 
Thanks again! I will definitely look into that since I plan on having side viewing panels as well. So I'm thinking that the 3M 5200 would be used for the window frames (extended out a couple inches of course), then silicone in the glass (which supposedly sticks to the 3M 5200), then have my zavlar cover the rest of the 3M 5200 up to the silicone?

Getting my viewing panes properly installed seems like the hardest part, hope this is the way to do it.

could I possibly do the entire inside of the tank in 3M 5200 sealant if cost allows and forget about the zavlar? I notice it comes in black, but can't find a price or quantity yet.
I sent them an email and notice they have a head office only 1.5 hrs from me, so this product should not be hard to get.
 
ok, so I found some price and quantity of the 3M 5200 sealant... looks like 1.2 gallons (in 12 caulking tubes) for just under $300. Now I gotta figure out how much of this stuff it's going to take to do the entire tank if that's the way I go. any ideas of how thick of a coat is needed? I can't seem to find the build that used this product (and I've read a ton of builds on here preparing).

here's the link I am referring to:
http://www.shop3m.com/60980109353.html

I'll have the entire back of the tank (9'x30") to do, entire bottom (9'x3') and 3 frames.. sounds like I'll need alot of this stuff...

thanks again for your help ross! I read your build and it was fantastic! you seem to be the only one helping me out here.....
 
I don't have personal experience with 3M 5200 but my understanding is that it's more of an adhesive/caulk and isn't intended for waterproofing large surfaces. I'm guessing that it's going to be prohibitively expensive and won't be practical for what you're suggesting. If you have Zavlar available I would use that - it would be a much better and cheaper option.

Crispy;4368175; said:
So I'm thinking that the 3M 5200 would be used for the window frames (extended out a couple inches of course), then silicone in the glass (which supposedly sticks to the 3M 5200), then have my zavlar cover the rest of the 3M 5200 up to the silicone?
Click to expand...

I believe that Ross was suggesting that you use the 3M 5200 instead of silicone not in addition. Silicone does not adhere to Zavlar but 3M 5200 should adhere to both the glass and (supposedly) Zavlar so the silicone is not necessary. Personally, I think the safest and more foolproof method would be:

1. coat the window frame and a few extra inches with a few layers of good quality 2 part marine epoxy (eg. West Systems 105)

2. glue in your window with butyl rubber, polyurethane caulk, 3M 5200 (probably the best option) or regular silicone (probably the worst option, but should still work since it's being applied over the waterproof epoxy layer).

3. paint the rest of the tank with zavlar, applying over your epoxy strip and up to your adhesive layer.
 
ok, thanks again. now it's just a matter of if the 3m stuff will adhere to the zavlar. planning stage is almost complete!!
 
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