New DIY Kalk Reactor

[Mikeydog]

Well here is my new Kalk reactor. This is my first experience with acrylic. I think It turned our pretty well. Right now it is being wet tested in a big bucket. Hopefully I’ll have it installed by tomorrow or Sunday. Anyway here are the steps that I took to build it. Most of this is based off of a design I saw on Reef Central from Platapus. Thanks

Picked up some acrylic at a local plastics company. Went ahead and had him cut the acrylic. Used a Rotozip to Cut two of the 8� x 8� Acrylic pieces into 6 ½� Diameter Circles, then cut a 3 ½� hole in the center of one of the circles to create the flange for the top of the reactor. Drilled 8 5/16� holes in the lid and the flange for the bolts that hold the lid on. Tapped the holes in the flange so I wouldn’t need nuts. Drilled a 1� Hole using a hole saw in the lid for the ½� JG Quick disconnect also tapped it. Drilled a 7/16� hole in the lid and tapped it for the ¼� JG quick disconnect. Glued the flange onto the Acrylic tube using Weldon 3 and using the little pin trick as mentioned numerous times on Reef Central. Drilled 2, 1 1/8� holes using a hole saw in the bottom for the ½� bulkheads. Assembled my stand/box with the precut pieces using Weldon 3 and the pins once again.

Most of the parts
http://4.47.231.7/memberpics/mikeo/kalk01.jpg

Pump Setup and Plumbing
http://4.47.231.7/memberpics/mikeo/kalk02.jpg

Used the male threaded ½� 90 on the input side of the Mag 2, and used the female threaded ½� coupler on the output side. Cut plumbing to size, so that the pump would rest on the floor, taking all stress off of the box and the bulkheads. Then Cut internal plumbing to size. I put an elbow on the pump input line so that when I dump Kalk in the reactor it won’t accidentally get into the pump. I also made the pump input line rather tall, so it would suck clearer water, to help extend the life of the pump. I angled the pump outlet down and to the left so it would make a swirling motion when mixing up the kalk. Mounted a female ½� coupler to the bottom part of the ½� JG quick disconnect that stuck down into the reactor, then attached a rather long piece of PVC to the other end of the coupler to force fresh water into the lower half of the reactor.

http://4.47.231.7/memberpics/mikeo/kalk03.jpg

http://4.47.231.7/memberpics/mikeo/kalk04.jpg

Bottom side of the lid
http://4.47.231.7/memberpics/mikeo/kalk05.jpg

Fully Assembled and ready to go
http://4.47.231.7/memberpics/mikeo/kalk06.jpg

Acrylic - $60
3 – 8� x 8�
2 – 8� x 6�
2 – 8� x 4�
1 – 5�OD x 20�

Plumbing - $9
1 – Male Threaded 90 ½�
2 – Female Threaded Slip Couplers ½�
1 – 45 ½�
2 – 90 ½�
1 – 10’ ½� PVC Pipe
1 – JG ¼� Quick Disconnect
1 – JG ½� Quick Disconnect
2 – ½� Bulkheads

Misc
1 – Mag2 Pump - $34
8 – 5/16� x 2� Nylon Bolts - $3
1 – 4 ¾� ID Rubber O-Ring - $1.50

Grand Total $107.50
Seeing something you built from scratch, up and running PRICELESS

I think if I were to do this project again I could do it for less money since I now know exactly what I need, and I also made some mistakes along the way and bough extra materials and a couple tools.

I also figured that I now need to purchase a Drill Press, and a Router.

Thanks

[Foster]

Very nice, that is exactly how I would of built mine ;)

Suggestion: Lower the pump intake so the it pulls water from the middle of the reactor instead of pulling water from the top were all the clear saturated water is......?

<img src=http://bluechunks.net/reef/225reef/plumb6.jpg>

[capescuba]

Looks awesome - I am also in the final stages of building a Kalk mixer. very similar to this and also the one posted by greeneyedblackcat(sp?).

Anyway, one question I have, how are you feeding your RO into this? I have a mini-jet 606 and am planning to hook that to a float in my sump, which will in turn feed my mixer. Sound about right?

[capescuba]

Here is mine so far ...

[Mikeydog]

Nice Setup Capescuba.

I built an auto top off system http://archive.reefcentral.com/forums/showthread.php?s=&threadid=309128 which will pump water into my kalk reactor and then into the tank. I will also plumb a bypass using JG quick disconnects, to bypass the reactor if needed.

Platapus: don't I want to keep the pump from pulling cloudy water which has kalk suspended in it, for fear of clogging the pump up??

[Foster]

I guess that depends how long you pump is going to run for? Mine will be running for 60 secs every 6 hours. I havent started using it yet..... so the positioning is just me person thery. On some of the MFG kalk reactors, I noticed that there intkes are in the middle...

percisionmarine and MRC, to name a couple. Only time wil really tell ;)

[Mikeydog]

How much Kalk do you think you are going to dump into it?? I'm getting pretty antsy and will probably hook mine up live tonight..

[Foster]

I will probably start out with a 1/2" and see what that does? I really have no idea how much to put in there?

[Foster]

let me know how it works out foir you, I wont be ready for mine for a couple more weeks

[Mikeydog]

I don't know how you do it with your setup. I would never have enough patients to setup my tank like your doing yours. I wish I could but I get started, and then I just want it up and running.

[capescuba]

I have to go on vacation next week so the tank is on hold! I think 3-4 weeks for me ... :(

[Foster]

I dont know how I do it either :D

I had a hodge podge 100 gallon setup for 3 years, that was a nightmare, hoses leaking, rubberbands, and duct tape everywere, inadaquit flow...... I was bumbed out on it, since I spent so much time and money, and it was a wreck (I setup the reef first, then read about how to keep a reef tank second..Mistake).... So I had 2 choices, get out of the hobby, or tear it down, and complety redesign a new system from the ground up with all my issues resolved.

So when I get inpatience, and want to rush it, I think of the 30 gallons of salt water down my hallway, and the humming of emtpy pumps at 3:00am ;)

[Ereefic]

Mikeydog, your pics aren't showing up. Can you send them to me? Great project, going to have to try it myself. Thanks.

[Mikeydog]

Yeah sorry about that. I shut down my web server last night to play games. They should be up now..

[Ereefic]

Thanks.

Is the long pipe coming down from the top the fresh water inlet?

[Mikeydog]

Yes. That pushes the fresh water into the lower portion of the reactor, forcing treated water out the top..

[Ereefic]

You said you drilled a 1" hole for the 1/2" JG disconnect fitting and tapped it. I drilled a 1" and it's too big for the JG 1/2" fitting. You sure about that hole size?

Also, how far apart did you make the holes for the 2 bulkhead fittings?

[Mikeydog]

Yes that is correct. I used a 1" hole saw to cut the hole and used a 1/2" NPTS tap to tap it..

On the bulkheads.. Not very scientific but all I did is mount the bulkheads on the pump and then turn the pump over on the acrylic and thend lined it up where I wanted it and let the o-rings fall down, then pulled the pump and left the o-rings. Then marked it and drilled it using a 1-1/8" hole saw

[Ereefic]

I must have gotten a similarly labeled, but different sized fitting, but it's all good. :)

I asked about the bulkhead holes because I don't have the pump yet. Was hoping to get it all drilled and just hook up the pump and test her out.

How is everything going with yours? Any changes you would make if you did it again?

BTW, thanks for the thread and pics, been very helpful.

[Mikeydog]

Glad everything worked out for you.

I have had mine running for over a week now now problems. I have the pump on a timer. Stirs up the the kalk 2 times a day. I really like watching the cool swirl effect it creates. I push about 2 gallons of water through it a day.. My PH in the tank sits around 8.1-8.4

I actually was out of town for the extended weekend, and everything worked like a champ..

[reefscapes]

I like your design. Just wondering if you will have any issues with servicing the pump in the future. It seems like removing the bulkheads is the only way to remove the pump from the assembly. Will you have enough room to fit your hands and possibly pliers to deal with the bulkhead nut?

[Ereefic]

I noticed that myself reefscapes. I'm building the same one, just hopeing to throw 2 unions in there for easy pump removal. I say hopeing becuase I don't have unions here or a pump for that matter so not sure if they'll fit .

[Yam]

I would add some bracing to the support acrylic. Once that thing is filled with water, its heavy. A small bump, and the joints will crack and likely tip over.

Its almost identical to the Reeftek models.

BTW, I add in a pound of Kalk at a time.

-Yam

[Foster]

Im using a 6"OD tube which I can fit my hand in to remove the bulkheads.

[Mikeydog]

Reefscapes: I actually just siliconed the pump intake and output into the bulkheads. The pump sits on the ground and I cut my PVC lines comming and going from my pump the perfect length to fit into the bottom of the reactor, so I don't have to worry about it falling out of the bulk heads. If I need to service it. I just drain the reactor flip it over, yank the pump off and then I can unscrew my fittings. Easy as Cake.. Also I can reach into mine also and unscrew the bulkheads if needed.

Ereefic: I don't think some unions would fit under mine. You could easily make your stand taller though to accomidate some unions.

YAM: I was going to use some pipe strap (that flexable nylon like stuff) to mount my reactor against a wall so it doesn't get knocked over.

[Mikeydog]

Platapus: Well it has been running over a month now with my auto top off system and I am more then pleased.. I basically dose through the reactor all day long, since the float switch in my sump trips at least 10 times a day, I'm only putting about a liter in at a time. My PH never pases 8.4, usually fluctuates from 8.2 to 8.4 throughout a 24 hour period. Very cool.. Thanks again for the inspiration.

[capescuba]

Just when you thought a thread was dead !

Quick question on draining your mixers - Do you have gates at the bottom to drain them? Just tip it over into a bucket ..??

I have modified mine to add a gate at the bottom between the pump and bulkhed - Does't look as clean and compact as your designs, but server a purpose notheless.

[Foster]

Mikeydog: Glad to hear that all is working, I havent got mine up yet...hopefully another week! Are you running a calcium reactor too? Also, are you running all your top off water through the kalk reactor?

capescuba: Idont have a gatevalve, I plan on doing the dump out, hopefully I shouldnt have to do this too often.

[reefscapes]

Thanks Mikey. I might go with some unions for more secure joints. Downside is it makes the entire structure taller than desired. Can't have everything in the DIY world.

[Ereefic]

Originally posted by reefscapes
Thanks Mikey. I might go with some unions for more secure joints. Downside is it makes the entire structure taller than desired. Can't have everything in the DIY world.

Sure you can, if your putting the reactor on a table, cut out a hole a little bigger so the pump will sit down in it. Know what I mean? :)

[Mikeydog]

Capescuba: I didn't plumb any kind of drain in it. I figure I can just dump it out if I ever need too.

Platapus: Yes all my top of water is running through my Kalk reactor. And Yes I do have a 2 chamber DIY calcium reactor.

Reefscapes: Well if your worried about stability with making the stand ie. the whole thing taller. Make the stand a little wider also, that will help compensate for the added height. I can't imagine you would need more then an additional inch or two. Come to think of it. If you get a union with a threaded end on one side you can get rid of the coupler on the output side of the pump and it may fit..

[Mikeydog]

Here is a repost of my pictures, my ISP changed my IP address and I have no way of editing my original post.

http://4.47.230.29/memberpics/mikeo/kalk01.jpg
http://4.47.230.29/memberpics/mikeo/kalk02.jpg
http://4.47.230.29/memberpics/mikeo/kalk03.jpg
http://4.47.230.29/memberpics/mikeo/kalk04.jpg
http://4.47.230.29/memberpics/mikeo/kalk05.jpg
http://4.47.230.29/memberpics/mikeo/kalk06.jpg