DIY Thread Wheel
 

    I have been following this thread on Reef Central which people are converting their needle wheel impellers and their standard paddle type impellers into a 'thread wheel impeller' for optimal performance with their protein skimmers.

    'Mavgi', likely the largest contributor to this thread, has sent me a generous size sample of the P4 and P5 mesh shown on this page.

    There are MANY ways to do a 'Mesh Mod' and this way may NOT be the best. This page will likely be a long term 'work in progress' so it may change daily.

 

The Goal:

 

Step 1~ Modify A Stock Paddle Impeller

     Grind or cut away the majority of the paddles from the impeller then cut off the remaining portions of the impeller using a razor knife.
   
   

     This is a simple Jig I made to cut the impeller.

 
     
   

     Make sure that the table saw blade is set LOW! Place the impeller on the jig, turn on the table saw and begin slowly and carefully raise the saw blade. Once the saw blade begins to cut into the impeller, begin rotating the impeller. Keep adjusting the blade and rotating the impeller until you've successfully trimmed away all of the paddles.

     

     This may not look pretty, but it does the job.

 

 

Step 2~ Make An Acrylic Disk

       I purchased a Circle Cutter from my local Ace Hardware store.
     
       I used scrap sheet of 1/8" thick acrylic. Drill a guide hole using a drill bit the same size as the drill bit in the Circle Cutter. This is important to do in my experience with the Circle Cutter. If you DO NOT start with a guide hole then THIS will likely happen.
     
           I put the Circle Cutter in a variable speed drill press and cut approx 1/2 way through the acrylic sheet. Flip the acrylic over and finish the cut.

 

VIDEO OF CUTTING A DISK  
     I believe the chuck in this drill press may be a bit crooked or something ... friggin annoying!

 

 

Step 3~ Drill Out The Center Hole

Before: After:    
       I drilled out the center hole to fit the GX2400 paddle impeller using a drill press. I also drilled 8 smaller holes surrounding the center hole using a smaller dill bit.

 

 

Step 4~ Glue The Disk To The Impeller

     I glued the disk to the impeller using super glue gel.

 

 

Step 5 ~ Attach The Mesh

     Home Slicker Mesh     PF4A Mesh PF5 Mesh All 3 Types Of Mesh
                             
     
 
EnkamatŪ Type

  Overall Thickness 

  Fiber Diameter 

PF4A EnkamatŪ Nylon 

.25"

.020" 

PF5 EnkamatŪ Nylon 

.50"

.025" 

 

 

    I used the P4 mesh. I cut 3 layers for this impeller. Many have tested the PF4 and the PF5 mesh and say that the P4 is the best of performer of the 2.
         

     I first tied a fishermen's knot (like tying a fishing hook) and glued the knot using super glue gel. I weaved in and out of the holes all the way around the disk, tied off the knot and used super glue.
         

     I then trimmed the mesh around the disk using scissors. The mesh appears to be 'puffy' along the outer edge.
         

     I then wound the excess fishing line around the outer edge of the disk to make it look more even.

 

First Day In Use
After Approx 1 hr   After Approx 2 hrs   After Approx 4 hrs   6 hr Close-up
     


    From reading this thread on Reef Central it is evidently common for the skimmer go undergo some changes during the 'break-in period'. Some have reported instantaneous improvements and some (similar to my experience) have to wait for the improvement to kick in. Regardless what results you witness at first, it WILL IMPROVE WITH TIME!




 

Second Day In Use

    I woke up this morning to find a collection cup full of almost clear skimmate. I forgot to lower the water level within the skimmer before going to bed. Evidently the skimmer drastically improved sometime throughout the night and filled the cup with way too wet of skimmate. I had to lower the water level about 3" in order to run my skimmer at all. That's a sign that I'm getting MUCH MORE AIR!

 

     For those who use 'Flowmeters' to measure air volume, I have created a Microsoft Excel conversion calculator to convert schf to liters/min and liters/hr.

    ~ Conversion Calculator ~

 

 

   Here is another method of making an acrylic disk.

Step 1~ Modify A Stock Paddle Impeller

  Stock GX-2400 Paddle Impeller

 

  Grind away the majority of the paddles flush with the rim. This is easier to do in comparison the the previous method shown above, but leaves less room for mesh.

 

Step 2~ Make An Acrylic Disk

     I started with about 1/8" thick acrylic and cut out a disk using a hole saw. Best result will be found using a variable speed drill press. Looks messy.
     I then placed the disk in a lathe and reduced the outer diameter to about 1-1/2" which cleaned the disk up perfectly. Cleaning this disk up to perfection is not necessary, a little sand paper or a razor knife would do just fine.

 

     I drilled out the center hole to fit the GX2400 paddle impeller using a drill press and then placed the disk on the impeller.

    It would be beneficial to drill some holes in the disk in order to attach the mesh using either fishing line or zip ties.

 

 

 

 

GenX 2400 Needle Wheel Impeller
Fig. 1 Fig. 2 Fig. 3 Fig. 4

     The GenX-2400 needle wheel is constructed of 2 pieces glued together (best seen in Fig.3). The outer half of the needle impeller can be removed by carefully pulling it off. Mesh can be cut and zip tied to the lower half of the impeller.

 

 

 

 

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