building polycarbonate sump

[Bass Master]

I was wondering if anyone has tools/skills to cut polycarbonate sheet. I believe it's 3/8 thick. I have the tools and could make jigs but I was hoping someone has experience with this and could help/give hints. Thanks.

[SunDragon]

What shape are we talking about? Squares not a problem here for the table saw.

[Bass Master]

Everything square. Just a basic sump - wet-dry on the end with a refuge in the middle and the return on the other end. I'm having problems with bubbles from my return. The sump I'm using now is a rubbermaid container and there is no way to install baffles. It's under a 30 cube so space is a prob, that's why the rubbermaid

[SunDragon]

Not a problem then. I can cut up to 36" on my tablesaw. By polycarbonate, where talking like that white plastic material right(not that it matters)? Or are you talking about acrylic, or plexiglass?

[Bass Master]

Sheffield plastics
makrolon
polycarbonate sheet
none tougher none clearer
This stuff is shatterproof, unlike acrylic or plexi. More info at sheffieldplastics.com. It's 3/8 thick. Later.

[manderx]

does it glue-up the same?

[SunDragon]

looks like darn tough stuff. I didnt see anything about cutting it though. You might want to give them a call and see if you need a special blade or something to cut it.

[Bass Master]

I built a wet-dry for a 5gal sump under a 7gal bf. So far so good. Thinner material of course - figured 3/8 was a bit overkill just for a wet-dry box. Used, will be using weldon #16.

[Bass Master]

I think I will cuz' I just read on the protective layer to use only non-hardening, low modulus sealants compatible with polycarbonate. The wet-dry box has done fine, but I don't want to take a chance with a sump full of water.

[Bass Master]

SunDragon - I just talked with tech support and he said a sharp carbide tipped blade will work fine. Just keep vibration down to a min. Also the weldon 16 is fine. The reason for using the non-hardening type would be for window/store front application - to allow for expansion.

[SunDragon]

Ill check my blade when I get home, Im pretty sure its carbide.

[Bass Master]

If not I'll pick one up when the time comes. I really appreciate your offer to help. My main thing is figuring out where to put baffles etc. I know your doing mostly sps so I don't have any frags, so maybe I'll pick up some Hooters wings and a 12 pack.

[SunDragon]

not necessary, im just happy to help out. ive laid out a couple of sumps now, so let me know if you need help with that too.

[Bass Master]

Thanks. I just did some measurements and I've got about 23" side-to-side and 21 maybe 22" front-to-back. Height isn't an issue. What I have now is a little over 17" and could go either way. Thanks again.

[Bass Master]

They faxed me 18 pages of info. Even has a graph on wind load resistance.

[SunDragon]

good to go on the blade. When you get your dimensions all figured out let me know. Shouldnt take an hour to cut the pieces.

[Bass Master]

Thanks and will do. Later.

[AQUAN8TOR]

I didn't know you could use 16 for polycarbonate. I thought it was #5. oops. Good to know, though. Scott, do you know if you can link polycarb to acrylic with 16??? I got a piece of 6" dia. stuff for free, and was going to build a nilsen reactor for kalk topoff, but didn't b/c I think it's polycarb, not acrylic. I'm too lazy to search the IPS site.

[Bass Master]

Nate - It doesn't really say if you can bond it to acrylic. I'm sure I can get you some polycarbonate though. I'm looking at the adhesive guide and it recomends weldon (and various other adhesives) in "various viscosities offering quick bonds". Setup time 1 min, cure time24 hrs. Also says to let the material soften, then clamp until bondis set.

[AQUAN8TOR]

I might take you up on your offer....I only need a little. Say, three pieces 8" square??

[Bass Master]

Not a problem. How thick?

[Bass Master]

I can get that for you today if you need. Give me a call later. It'll be after 5:30 till' I can get it.

[AQUAN8TOR]

3/8" is preferable, but 1/4" will do. I'm going to spin it on a router table to make flanges. 3/8" is definitely better. I'm going to try to spin a groove to put an o-ring in. First time for that, so I'll let people know how it turns out.

[Bass Master]

3/8 is no problem.

[Bass Master]

Nate - I have what you need. 4'x 8.5" x 3/8.

[AQUAN8TOR]

Sweet!! Didn't get home til just now, so I'll call you tomorrow--wednesday.