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Old 08/13/2017, 11:30 AM   #1
Clowning_Around
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Fun DIY $5 Bulkhead Tool & Bonus :)

I had been using a piece of wood cut such that it was wishbone shape to use as a tool in either the wrench or in socket position. Simply a scrap piece of 2x6 notched on the end the width of the nut. This works but in another thread I read from Gorgok how he used a piece of 3in pvc to make a socket. I liked this idea and really liked how if I had one aswell it would keep me from having to keep up with a big clunky piece of wood with my aquarium supplies. I didn't see a dedicated thread on making this tool so I decided to photo document my effort and make a thread for others.

I don't know if it this is a commonly known / borrowed idea in the hobby but I give credit to Gorgok for the concept or atleast my first exposure to this concept.

So to start I needed supplies, specifically pvc for a 1.5in bulkhead nut, that I was wanting. I started at my local HD, a 3in pvc pipe but knew it barely covered the profile of the nut (brought ot with me ). I looked for various pieces that could slide inside to double up the wall thickness which I recalled was needed. While I was looking at the plumbing supply aisle for a slip plug insert, a reducing adapter bushing or a dbl'd threaded plug/cap I quickly was reminded of how limited the typical selections where for 3in pipe. Intially, I ended up with a 2 ft. piece of 3in pipe and a floor drain insert in my hands but kept shaking my head thinking there had to be a more cost effective way to do this. I know, I know... I was being cheap but I also knew I didnt want to spend much given I still had my old handy wooden tool . I did have pvc primer and cement at home and given such little would be used I wasn't factor that into the cost. For anyone who doesnt already have this you can grab an 8oz can of each in a combo pack for a little under 9 bucks, but I'm assuming we all already have this for other aquarium plumbing needs, especially since we're talking bulkheads here. So back to the supplies, in short I ended up over in the electrical department where pvc conduit is sold. They have 2.5in size sch 40 gray pvc and the ends are flared on one end for slip connections, I thought great, however a 10ft section and 15 bucks , to much waste and to much dough. Then I noticed a 2.5in pvc 45 degree sweep elbow - 5 bucks, Perfect!

So onto the pics....

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w

Last edited by Clowning_Around; 08/13/2017 at 12:08 PM.
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Old 08/13/2017, 11:31 AM   #2
Clowning_Around
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Square up the end of the warped flare and cut at these two locations

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w
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Old 08/13/2017, 11:32 AM   #3
Clowning_Around
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Prime both end pieces and cement the two together as pictured

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w
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Old 08/13/2017, 11:36 AM   #4
Clowning_Around
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Cut off the excess flared end after cured. Use the nut as a template to trace the profile onto the end of the pvc. A second hand helps to keep it steady and a felt tip pen works well on the pvc face.

Next clamp it in place, I opted for some wood clamps instead of my bench vise to avoid a big mess in my garage. Which ever avenue you use, make sure its secure and has a stable base.

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w

Last edited by Clowning_Around; 08/13/2017 at 12:10 PM.
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Old 08/13/2017, 11:45 AM   #5
Clowning_Around
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Next go ahead and freehand route the profile with the depth set to the nuts height and a little extra for play (A dremel will work if you don't own a router). I ended up taking the line off in the route but only after taking it slow with several passes and test fits. Ultimately, I decided to go a little strong for added play so as to accommodate variation in different plastic nut sizing knowing this is not for use with a tremendous amounts of force. Some of the small/thin remaining inner piece tabs wanted to peel away from the outer double wall. I simply reapplied some additional cement after to secure them again. Conduit pvc being a bit more asymetrical in tollerance led to some bigger seams than plumbing pvc but still fine for this purpose, the additional cement did the trick. Lastly, I drilled 1/4 inch holes at 45 degree incriments through pvc's perimeter at the opposing end for a screwdriver use as a leverage handle with various positions.

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w

Last edited by Clowning_Around; 08/13/2017 at 12:16 PM.
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Old 08/13/2017, 11:46 AM   #6
Clowning_Around
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Now the bonus... remember that middle part of the 45 section, why waste....

Its a free QT elbow

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w
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Old 08/13/2017, 11:48 AM   #7
Clowning_Around
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Be warned even though this design has the screwdriver handle for leverage don't overrtighten your bulkeads and risk breakage. Its best use is for old stubborn bulkhead removal.

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w
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Old 08/13/2017, 01:04 PM   #8
ericarenee
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I have a whole set of these . i think ridgid or Milwaukee brand in my Plumbing box out in my van.. Mine has a long handle with a slit longways to fit over water lines. Kinda like a brake line wrench ..

but nice work none the less..


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Old 08/13/2017, 09:03 PM   #9
Clowning_Around
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Thanks, yea if I had a set of lg sockets that would have been ideal but this was fun too, so all good...

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Build http://www.reefcentral.com/forums/showthread.php?t=2638892
Parameters: Temp 77-79degF, Specific Gravity 1.023-1.024, PH 8.1-8.4, Alk 8-12, Ammonia 0, Nitrite 0, Nitrate 0, Phosphate <.2, Calc 3

Current Tank Info: Custom Oak Stand | 75G FO Display | 40G Breeder Sump | MarinePure Ceramic Media Plate | Eshopps x-120 skimmer | Mag9 Return | Aqua Ultraviolet Advantage 2000+ 15w
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Old 08/13/2017, 10:10 PM   #10
Gorgok
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Quote:
Originally Posted by ericarenee View Post
I have a whole set of these . i think ridgid or Milwaukee brand in my Plumbing box out in my van.. Mine has a long handle with a slit longways to fit over water lines. Kinda like a brake line wrench ..
Yeah a crows foot design would have been nice, but then it can't really be made out of scrap pvc i think. At least not the 70mm size i made. Plus now i have a really really deep (about 3 feet) 70mm socket.

Nice find on the conduit too, i really can't remember what the pipe i used was or where i got it. I think it says NOT FOR PRESSURE NOT FOR PRESSURE all the way down its side though.


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