YEAH! It's done!
I spent the whole day making the canopy and have to say I'm really proud of it. There's little gaps and glitches I didn't expect, but all in all it's working absolutely great and there's nothing I'd change about it.
Here's the assembly more or less together. It's a box but I welded in a couple of angled pieces of polycarbonate and siliconed mirror tile to them. That's helping reclaim quite a bit of light. It's no parabolic reflector, but it's still doing a tremendous job.
Mirror tile is really, really nice to work with. I've done a lot of work with plate glass and this stuff was a joy.
See the seams there? The tiles were 12X12 but my canopy is around 14" so I had to splice it. Don't ask why the splices are different lengths, it's stupid...
The bottom (from this viewing angle) is the hole cut for the fan. I got a PC cooling fan to do the job and cut the hole with a jigsaw. Then I smoothed the hole with a sanding disk we have that fits into the drill press. The top is where the mogul socket for the PC light slips in. That took the most work early in the day. More on that with the next pic.
Here you see the box with the wedges welded in. The mount for the light socket is 4 layers of polycarbonate welded together (1" total thickness). I sanded the holes open after that to get a really tight fit. I don't have to fasten the socket in or anything - I had to get it in there with a mallet and it's not slipping out any time soon.
Here's a view from the fan hole side. Note the direction of "up". I feel it's important to leave visual cues for people.
The LED supplementation was pretty easy once I'd worked out what power adapter I could use.
See, that's the most annoying freaking thing about the whole project... A DC adapter has a listed voltage and current on the back... Which is totally meaningless for this purpose. Basically it says that when you have a device plugged into it that draws the rated, say, 100mA, then it will get 12V. If you aren't drawing 100mA, you get MORE voltage. When an LED gets mad and explodes like hell with too much voltage, that doesn't help.
Even worse, I didn't have any adapter (and I have 10 of 'em in my electronics box, too) that could run both the fan (I need 10-12 volts) and my LEDs without the voltage collapsing due to the high load. Thus, the fan itself is running at around 13V (and noisy as hell, though fortunately the grinding-snarling-vibrating "QUIET ONE" pump totally masks that) and my adapter for my LEDs puts out around 7V.
Ok, enough whining. Here's what happened:
I used polycarbonate to make the casing for my LEDs. Why? Because it was there. Shut up. Next:
I drilled holes at an angle so that the LED casing can be mounted at the front of the tank but shine towards the middle. I deliberately did NOT measure the distance between LEDs nor the exact angle so the light would be a little more random. Above you've got the blue LEDs freshly glued in. I decided to take a chance and use Weld-On to fasten them in. I think LED casings are made out of epoxy... Seems that Weld-On is compatible.
Front view of said LEDs.
Hey, that guy on the top left of the page is being sentenced for his role in a plot to bomb an airport. He looks pretty uncouth, if you know what I mean.
Here's with all LEDs in and soldered together. Like I said before when I was whining, the power supply gives me around 7V for my LEDs. These LEDs work best at 3.3VDC (ie. any less and they're not that bright, any more and you're pushing them too hard). If you don't know electronics, you can wire devices in series to get an additive property for voltage - ie. two LEDs in series means that only 7V/2 goes through each - 3.5V (the meter tested it at 3.2V). That's safe. Then, in order to get them all connected, I wired each group of 2 in parallel (voltage remains constant across a parallel circuit). I clipped as much of the leads and wire as possible and smooshed them into there and cemented on another wall.
Front view. It almost looks like I took high school electronics, doesn't it? In fact, you can tell I did from all the spit everywhere - where else would you learn to strip wire with your teeth and get yelled at because it's bad for your teeth?
Last I made small caps and drilled a couple holes for the power leads out.
Top view of the finished product (sorry 'bout the blur - I was lazy and only tried to take one shot). It's not lit there - that's just reflection from the overhead lights.
Inside view, man. I added mirror tile to every side surface (not the ends, though.. Way too many angles to work out for such small gain when you consider the way the bulb is situated). The bolts holding the fan on are stainless. There are no nuts on the other side holding it on... What? Yeah, turns out it's such a tight fit on the fan there's no room to screw the nuts on. No prob, it's not going anywhere.
I did have one ghetto moment there... I had no electrical tape for when I soldered the power leads from the fan and LEDs to the DC adapters.... I had to use scotch tape.
And, finally, after all that agony, here she is:
I'm not totally decided on the aquascaping. I had 3 other pieces and just chose 3 that sort of sit in there the easiest. The others are in my 65 finishing curing (oh shut up, they barely smelled anymore and my cleaner shrimp love that kind of crap).
I didn't buy that calendar and I only put it up to make my mom feel better.
Oh, the supplemental LEDs? Don't show up. At all. Not even worth taking a picture. I'll use 'em as moonlights. I'll post photos of THAT after I have some corals in there and you can see the UV LEDs making them fluoresce.
Needless to say the skimmer isn't running at the moment.
I still need to:
shut up the overflow
take the QUIET ONE pump and.... yeah.
get skimmer goin'
paint the exterior of the canopy black.. There's some light leakage still.
add a third U tube for redundancy.
And that's it. Hope you enjoyed my progress!