794 gallon ply tank build

[colty]

Finally I have decided to get my rear end into gear and get a start on this monster.A few pics to start with and then it will be updates as I progress with this build. It wont happen overnight but it will be slow and steady.

The dimensions of this build are 2636 x 1140 x 1000mm for those of us that know the metric system is the way to go. A total of 3005 liters.
For those yet to realize the pure genius of the metric system, that equates roughly to 104"x 45"x 39" A total of 794 gallons.
I should state these are internal dimensions.

This tank will be fiberglassed inside and out to ensure it lasts for a very long time and to eliminate the need for external framework. Fiberglass will be 2 layers of 600chopped strand matting using polyester resin. This will be coated with West Systems epoxy so it is fish friendly.
Onto the progress pics.

The first pic is just the ply ready to go. Overall dimensions of the sheets are 2700 x 1200 x 32mm or 106.2" x 47.24" x1.26" Structural ply.
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Pic of how thick these sheets are. I wanted to go thick for two reasons. First to eliminate external bracing and secondly to help with insulation. This tank will be outside. Under cover but outside none the less.
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Next pics are just me taking a couple of rips off three of the sheets. The fourth will stay as its original size and become the bottom.
I took two 98mm( roughly 4") rips of each which left me with a 1000mm/ 45" height to use for all sides. The rips will be used later for internal bracing.
As you can see, I use another sheet for a straight edge to perform my cuts. You can see the nail to hold it in place. Leave the nail proud so it can be easily removed once you have finished your cut.
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You can see some of the rips in the foreground to be used as bracing.
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Here I am cutting out the front sheet. I used a hole saw in all the corners and the cut the rest out with the circular saw. All edges will still have to be rounded off to make it easier to apply the fiberglass.
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The sides are only pinned together here but this gives some idea of the size. That's my son in the pic by the way. He is really getting into this build.
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Putting the lad to work. He is on school holidays at present so I may as well make the most of it.
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Getting another sheet screwed off. It is upside down here but I am sure that was obvious. All the screws are counter sunk. Screws are roofing screws as I have hundreds of these laying around already. With this thickness ply they really get a good bite. I hope my mug didn't cause to much trauma
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Just a shot showing the screw alignment. Notice that the screws in the face are stepped to those on top. The row of screws in the middle are through the ply edges. The row on the face and the very back row are going into the internal brace. There is an extra brace still to go in yet.
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This pic shows some of the internal corner braces. These are the rips I cut earlier. There will be a corner brace in every corner so I can screw of all the sheets both through the ends and sides.
Bracing will be doubled up around the window area leaving a 50mm/2" gap for sealing in the glass.
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This is the last pic for now and where I am at. I will finish screwing off what I can while it is upside down. Then I will flip it with over (with some help) and start on the top and side corner bracing. I will also finish the double up of the bracing around the window area.
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I would like to see more pic and too see it up and running

 

[citrinelum]

cant wait to see your fish in there

 

[fish_master2000]

nice build so far man

 

[greenterra]

Wow that's a very heavy duty tank. Going to last you some good years that one will. I wish I could come by a deal like that on thick plywood.

Good call not mixing polyester resin for your fiberglass with an epoxy top coat - they will co-exist if done properly, but not very well. Not nearly as well as polyester to polyester or epoxy to epoxy. For your flood coat/top coat, are you planning on using the boat-kote epoxy as well? I don't think you'll have a problem but you might want to look into it's fish-safeness. I know some epoxies create by products as they cure called amines. Most of the time you can wash the by products off and be left with an inert, safe surface, but not with all epoxy resins, particularly if you get the mix ratio off a little bit. Just a thought!

Looks like a ton of work! I can speak from experience, sanding fiberglass reinforced epoxy is not fast, fun, or easy - especially inside a tank, and especially with a tank this large! one missed fiberglass "needle" too and you can give yourself nasty cuts on the stuff. Looking forward to updates - looks like it's going to be a great tank.

Thanks for the comments. This Boat Cote epoxy is pretty stable and free of the side reaction known as amine blush. It was one of the reasons I chose it.

 

[greenterra]

Haven't been able to get much done recently and what I have has been time consuming. I have got a couple of extra coats applied. One more sand and I will apply a final coat. I want to make sure it never ever leaks. I am of the thought, better to spend the time now getting it right instead of trying to repair it later when it is full of fish. Touch wood my theory works.

A couple of up to date pics. The flash makes it seem grey in spots but I assure you it is black.

 

[yogurt_21]

looking good, the black is definetly going to make your fish pop.

 

[Sirspifalot]

iss beuful

 

[K.Galvin]

looks great greenterra, looking forward to seeing pics of the glass installation.

 

[wolfsburgfanatic]

looks fantastic so far

 

[rallysman]

Fantastic work! That looks great.

I might add that it looks a lot like the one I burned (only bigger/more solid) where did you come up with the design?