DIY : Styrofoam Sculpture #2
 Figure 1
Here the tank is on its side with a wooden jig inside, which was built to lower the front glass into place. This is the 120g tank which the front pane had partially come off. I had removed it, polished it and then reinstalled it into place. There are no pictures or article on the polishing project, as I decided that polishing was not worth anyone's effort to attempt. Not shown is the hydraulic jack which was used under the wooden jig. After the edges were siliconed, the glass was slowly lowered into position to set. It was quite heavy, being 60" x 24" and 1/2" thick, and it needed to be spaced about 1/8" off the other glass during curing. Also shown below the tank is a stainless steel bracket I had built for the top and bottom. If my silicon repair is insufficient, the bracket will keep the tank from coming apart.
 Figure 2
Tank is upright, stainless steel brackets installed (not siliconed), and the tank was filled for the water test.
 Figure 3
Extruded polystyrene, or a DOW Styrofoam billet, sold for dock construction. Ironically, designed to float so well, it will hold up a dock, and I am going to sink it underwater.
 Figure 4
This is the filter system. Basically a powerhead using four sponge filters. The sponges are basically mat filters, shaped into a cylinder, 12" high, 5" in diameter. Two would probably be sufficient, so four gives me plenty of redundnacy. In the event of a power failure, enough bacteria will be at the surface to provide biological filtration. Also I can periodically clean out a single cylinder without worrying about ammonia spikes.
 Figure 5
Carved sections for the filter system around the back of the structure.
 Figure 6
Roughed out the front.
 Figure 7
I didn't think my carving looked natural, so I decided to add a sedementary look to the structure.
 Figure 8
Started planning and carving the cave network.
 Figure 9
Caves completed. Still looks very artificial, however I'm making this for the fish. I want it to look attractive, but first I want the fish (Julidochromis regani)to fit in these caves, be able to move around in them, and they should be spaced from each other. This is what governs much of the design. There are also about 6 planters built into the structure to have some Java ferns creep up the sides. With age, algae and some driftwood across the front, I think I can make it all look presentable.
 Figure 10
Dry fit into aquarium. Filter system ok. Thought about heaters, optimal light locations, canopy design and driftwood construction. I'm probably going to secure a small sheet of acrylic to the crossbrace to hold the ends of several pieces of driftwood which will drop vertically down and then across the bottom of the tank, hopefully resembling tree roots. The inspiration for this design comes from Mango grove estuaries, which are home to many tropical fish.
 Figure 11
Painting completed, used about 6 colours, mixed into 16 colours for the different 'stone layers'. I'm ready to start the epoxy sealing. Is it starting to look less artificial?
 Figure 12
Before epoxy sealing the underside, I added a little more 'traction' surface for the silicone by routing a dovetail groove along the bottom. I normally only use a few drywall anchor screws, but this is a big structure with several hundred pounds of buoyancy.
 Figure 13
This close-up shows the groove, which should be small enough to not require an excessive amount of silicone to fill. A proper bit is probably available, but I used a flat head bolt with a few slots filed into it. Styrofoam is very easy to carve, especially with a router.
 Figure 14
Structure has been siliconed into the tank and the driftwood arranged for dry-fit. I need to design and build a plate (clear plastic) to hold the ends of the wood, and decide whether to incorporate that into the glass canopy or not.
 Figure 15
With water & fish (Monodactylus don't stay still for pictures very well). Secured some of the wood to a small piece of plexiglas. Eventually I'll design a proper stainless steel cover, but for now, I have a shop light (twin 40W bulbs) over it. Slowly I will plant it as I discover what the Julies don't tear up and the Monos don't eat. Right now there is a bit of E.tennellus in there.
NetMax
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