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Title: Baffle Construction Procedure Materials/Tools:
• Tank on Cart • HDPE Custom Table • 2” PVC Pipe • 1.5” PVC Pipe • Ball Valve • Diverter Valve • 2x Gate Valves • 4x Unions • 2” Pipe Straps • Screws • Form-‐a-‐gasket • 5x Bulkhead fittings • 2” PVC tee • 2” PVC elbow • 1.5” to 2” Coupler • Hole Saw • Mask
Time to Complete: 20 hours Procedure:
1) Sand flat locations of holes on tank and mark locations for holes on tank (2).
Measure locations and mark crosshairs for holes on table (3).
2) Measure OD of bulkhead fittings, drill holes in tank and table.
3) Glue together table pieces
a. Press fit together all fittings-‐ secure bulkhead fittings
b. Prep for use of PVC primer and cement. Turn vent hood on and
put on mask to alleviate fume danger.
c. Prime and glue inlet piece. Note all unions will be made to have the
male side on the tank and table, and female fittings will be on the
hose.
d. Glue together most of pieces, test fit as you move along in gluing to
ensure the elbows are at 90 degrees. Do this by inserting the
subsystem into the table.
4) Press-‐fit together fittings, note that a coupling and an adaptor is required for
the pump union because the pump union output is 1.5” instead of 2”.
a. Secure bulkhead fittings to tank.
b. Glue together all fittings, as mentioned before, insert into bulkhead
fittings occasionally to ensure uniformity/straightness.
Testing/Debugging Procedure:
1) Take tank outside, shut all valves, fill with water to top.
2)
3) Look at all fittings, seals, pipes, for leak. Test union connection to hoses.
Note leaks.
a. Leak out of top and bottom bulkhead fittings.
b. Leak out of plastic plug.
4) Empty out tank.
5) Brainstorm solutions for bulkhead fittings
a. More compliant gaskets (problem is that the surface isn’t flat), at this
point we haven’t tested the bulkhead fittings in a more flat
environment (the table), cut out of gasket sheet. Solutions were not
readily available without ordering from McMaster.
b. Sanding flat surfaces-‐ not possible because the system is glued in
already.
c. RTV.
d. Form-‐a-‐gasket moldable gasket.
e. Silicone all leaking surfaces.
6) Solution picked: Form-‐a-‐gasket
a. Bought from local pool supply store.
b. Apply gasket to inside and outside of tank. Also apply to gasket and
to nut on the inside of the bulkhead fitting.
c. Secure bulkhead fitting to tank. Wipe away and sand excess material.