Ok, guys, girls and aero enthusiasts- I finally began putting all of the pieces together today!!! It would seem I can finish the whole build either by tomorrow evening, or next weekend- barring any unforeseen circumstances.
Today I focused on the mundane task of modding the deck bin into a chamber. Here's what was in the cardboard box the bin came in: (my friend took the pics on his phone and they aren't the greatest, but there wasn't much interesting to show today anyway- tomorrow I will try to take some better ones).
As you can see, the pieces simply lock together in a matter of minutes, and the interior walls are riddled with ridges and strange patterns which present a slight obstacle when trying to make properly placed holes for the mist nozzles. This is about the only negative I found about this box, and otherwise it is going to look very nice and work rather well consdering being an aero chamber is probably the last thing rubbermaid had in mind for these bins- but it's ironic how rubbermaid always lends itself so well to hydroponics and aeroponics, and now HPA
... Good ol' rubbermaid...
One of the things I liked about the bins is that they are also dual wall construction on the bottom panel, and with a little mod-ing, the bottom panel can be great for collecting the effluent spray and directing it out of a drain hole. The bottom panel has some troughs that I decided to consider when making the draining system. They happened to be higher in the middle, and lower at the front and back, so I only had to drill holes at each end, knowing the water will drain towards them as gravity sorts things out. I was careful to only drill through the first layer of plastic and not through the bottom, which required some careful drilling due to the fact that in some areas the underside was practically touching the top layer, I am assuming due to the plastic mold process and to create additional structural integrity.
Next was to figure out how to drain the effluent out of the bottom panel after making it to capture the runoff. I decided to use one of the JG bulkheads and figured I could just pop in a length of 1/4' jg tube out the back leading into a collection container (thinking a 1 gallon plastic milk jug at this point). I will hang the jug on the outside of my deck railing a foot or so below. I want to collect the runoff so I can analyze it for clues of what the plants are taking up nute and waterwise, and if the jug ever happens to overflow at any point, it will just drip into the flowerbeds below without issue. The only problem with this is that the bulkheads have a nut that has to be tightened from the backside and also need a rear washer to prevent leaking. I carefully cut a small temporary access hole in the top of the bottom panel with a utility knife to allow me to install a rear washer and the nut from inside the panel. After the bulkhead is installed, I will use a bead of silicone caulk to seal it up again (I left one end of the cutout attached to make it easier). My deck where I'd like to run the chamber has a slight drainage pitch, lower on the end farthest from the house walls, and I want to place the chamber on the left side of the deck perpendicular to the house, so I figured the lowest point would be the right side of the chamber, and that is where I put the bulkhead drain. I deliberated over if I ought to include more than one bulkhead just incase this one became clogged, but I rationalized the runoff would be quite small, and since I was including a root barrier above- I figured it would act like a screen to prevent dead roots and debris from getting into the runoff. I also plan to run low level chlorine in my nutes, so I doubt any sort of algea or slime would ever grow enough to cause issue. I originally bought some round seals for the bulkheads, but they distorted when I tightened the nut down, so I ran to the hardware store and got some flat rubber washers. Here's what it all looked like as I was working on it:
I also created the holes and mounted the bulkheads in the sidewalls for each of the 8 misters, but hadn't taken any pictures of that today (I will tomorrow). All of the bulkheads are inserted on all of the sidewalls now. All that's left is to caulk the seams of the bin, and around the bulkheads and install the mist nozzles. Also have to plumb the solenoids and jg lines around the outside of the bin and wire the solenoids in- but then the chamber will be complete, and I'll just have to finish putting all of the pump accumulator, timer, battery, etc together. I purchased another same, but smaller size bin for all of these components and will run a small line of JG tubing from this smaller "control center bin" coming off the pressure regulator across to the root chamber bin, along with the power wires for the solenoids.