Tank Assembly Steps

(1) Cut all plexiglas per the indicated cut scenario.

(2) On one of the whole 2ft x 8 ft side pieces, draw a grid using indelible marker to be used as a guide for packing the sand. The grid will be on the outside of the tank.

(3) On this same grid, indicate where holes are to be drilled for the sampling ports. It is a good idea to do this design, marking, drilling, and tapping, before the top and bottom pieces and flying butresses are attached to this one side piece.
(4) Drill holes for sampling ports at indicated points.

(5) Fabricate two separate side units (mirror images): Bond the top and bottom edges and flying butresses to each side piece. BE SURE that the one side piece has been marked and had sampling ports drilled before attaching edges and flying butresses.

There are NINE equally-spaced flying butresses to be attached to each side between the top and bottom edges. The end flying butresses are flush with the end edge of the side piece.

Note that the "edges" are attached to the side FACES, not to the top and bottom of the side panels.

One gallon of "WELD-ON 3" has been purchased for the chemical bonding.

(6) Align bottom piece and top piece with two side pieces and drill holes through, per hole placement approximately as on Tissa's drawings. Note that the top and bottom pieces are NOT chemically bonded to the side pieces.

16 holes on each edge, two between each flying butress. 16 x 4 = 64 holes total, for 1/4 in x 3 in machine screws. Provide for countersinking screw heads.

(7) Align end pieces with the entire unit and drill holes to attach the ends to the end flying butresses. Note again that there is no chemical bonding of the end pieces to the unit.

See Tissa's drawing for approximate placement of holes. Our holes are NOT three inches apart - our distance between holes is less than this.

Eight holes/screws on each edge should be plenty - (I have drawn 10 here).

Countersink the screws.

(8) Decide where ports will go on the end pieces for inlets and outlets of water supply.

(9) Drill holes in ends for inlet and outlets of water supply.

(10) A track system must be devised and added at each end, in the interior, to allow slippage of mesh screen perpendicularly into the 4-inch channel. Tissa's student used 1/4 in-thick pieces of plexiglas bonded to the inside to make such little channels. Our system is similar.