Plenum DIY

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MATERIALS LIST:

bullet1" PVC pipe cut into 2-3" pieces to be used as risers for the grid
bulletsheet of egg crate used as the grid
bulletenough PVC window screen to cover the grid 
bulletenough bags of aragonite sand with 1-2 mm grain size to create a 4" layer of sand
bulletseveral pounds of live sand or a detrivore kit to seed the sand bed with micro fauna
bulletelectrical cable ties

The Plenum:

bulletTake the sheet of egg crate and cut to the size of the bottom of the aquarium, less one inch. For example, if the aquarium bottom is 48 x 24, cut the egg crate to 47 x 23. 
bulletTake the 2-3" pieces of PVC and attach them length-wise to the egg crate with the cable ties. Make sure to spread them evenly so that the egg crate is well supported. Now you have the "grid". 
bulletNow wrap the grid with the window screen like you would a present. Make sure that the grid is well sealed so that no sand can make it's way in. You now have the plenum.
bulletPlace the plenum in the aquarium.

The Sand Bed:

bulletRinse the aragonite sand well, preferably with RO/DI water. 
bulletAdd some rinsed sand into the tank and back fill the space between the aquarium walls and the plenum. This will hide the plenum from view.
bulletContinue to add the aragonite sand a layer at a time. After each layer is added, add enough salt water to bring the water level to same height as the sand. Work as much air out of the sand by stirring it with your hands. 
bulletOnce all the aragonite is added, you can fill the aquarium with salt water and add the live sand or detrivore kit to seed the sand bed.
bulletIf possible, allow the sand bed to "settle in" for a couple of weeks before adding the live rock and inverts. In the interim, you can "feed" the sand with a small amount of fish food each day.

The Aquascape:

bulletMake sure to construct the aquascape as loosely and open as possible. This will allow good water flow throughout the tank which is important to the health of the tank. 
bulletWhen creating the reef structure, make sure to maintain as much of the sand bed exposed and unobstructed by rock as possible. Strive for a 70% exposed sand bed. Placing to much rock on the sand bed will inhibit the sand beds ability to filter the water of nutrients. 
bulletPlace power heads in areas where they will create a nice current across much of the sand bed. 

Maintenance: 

bulletDisturb the sand as little as possible. Vacuuming the sand is not necessary and is actual detrimental. The sand bed will be maintained "clean" by the micro fauna populating the sand. 
bulletDo not add any sand stirring critters such as Jaw fish or burrowing Starfish. These will quickly decimate the micro fauna populations necessary to maintaining this type of system healthy.
bulletRoutinely add small amounts of live sand or additional detrivore kits to keep micro fauna populations at desired levels.