Build the aquarium and raised-land enclosure

1. Qualify the full support and actual load

Parts: P01 — complete floor and finished underside; separate aquarium and land-bed loads

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use a level, rigid, continuous support at least 96.092 in (2440.74 mm) × 24.092 in (611.94 mm). Support the complete veneered underside, every edge and the aquarium’s complete maker-specified base. Qualify the actual furniture and building floor for the full loaded weight.
2. Use 600 lb (272 kg) only as a tank planning allowance, not a measured aquarium weight. Calculate the actual load from the empty tank, water at 8.34 lb per US gallon (1 kg/L), substrate, rocks and equipment. The conservative land-bed scenario adds about 272 lb (123 kg) at an assumed 100 lb/ft³ (1602 kg/m³). Add the entire shell and glass. This guide does not rate that load: the actual furniture and building floor must carry the total, with continuous support beneath the whole plywood floor and the tank’s complete bottom frame.

Check before continuing: The full underside has a continuous support plan, and the combined aquarium, bed, shell and equipment load has been referred for qualified support review.

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2. Plan separate transport and service routes

Parts: P02 — removable roof; GL/GR — upper glass; CAP1/CAP2 — equipment doors; separate TANK

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Allow complete roof removal above, supported glass service and 26 in (660.4 mm) cabinet swing/handling space in front, plus both side-vent cleaning routes. Veneered capture width is 96.811 in (2459 mm). Flush retainer heads add no projecting tails. Plan the empty shell and aquarium transport paths separately.
2. Do not stack enclosures, hang this box, climb on it or move it loaded. Plan separate furniture restraint to the actual wall structure if tipping is possible; this guide does not rate a stand or wall anchorage.

Check before continuing: The empty shell and aquarium have separate transport plans; front, roof and side-service routes have the required clearance.

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3. Resolve the product and veneer holds

Parts: Actual product samples and supplier replies

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Read H01–H14 before dependent purchases or cuts. Obtain KV acceptance for this steel system, wider panes, carrier geometry, adhesive mounting, right-jamb relief and removable anti-lift design. Save the supplier response; rejected details need redesign.
2. Choose ONE exterior species: maple, white oak or walnut. The schedule needs five 48 in (1219.2 mm) × 120 in (3048 mm) sheets with the approved PSA backer. Confirm panel balance, cured coating compatibility, humidity/heat/cleaner exposure, acclimation, pressure and dwell. A changed backing or balancing layer needs new geometry and quantities.
3. Approve the exact liner/underlay application and coating/cushion-bond samples. No received product or physical trial has yet been supplied. The open holds distinguish this digital candidate from construction acceptance.

Check before continuing: Required written answers are recorded before proceeding; rejected or unresolved substitutions stay on hold.

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4. Receive the wood and accepted steel system

Parts: Plywood, solid wood, frame and strip stock; accepted KV993/995/997/999 steel system

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Measure the plywood at several points. This plan uses plywood sold as 3/4 in (19.05 mm); actual thickness varies. Write down your measurement and use it when fitting the sides, back and frame. Reject separated layers or warped sheets. Check the square support strips are 1 1/2 in (38.1 mm) on each side and the frame boards are 3/4 in (19.05 mm) thick.
2. Receive matching steel KV993/995/997/999, 963L lock and PL Premium 1390595 only after H01 written acceptance. The current product page describes doors up to 36 in (914.4 mm); this wider reference pane needs acceptance of size, mass, adhesive mounting and the modified jamb. Older 12-foot-opening guidance is not a current wide-pane approval.

Check before continuing: Actual wood gauges and usable stock sizes are recorded; the accepted steel profiles match the receiving list. No final glass is ordered.

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5. Measure lining and mark the height strip

Parts: DECK — raised land deck; UNDERLAY and LINER; separate height-marking strip

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place the underlayment and 45 mil ethylene propylene diene monomer (EPDM) liner on a smooth plywood offcut and measure the compressed stack. It lines only the land deck; the tank bay floor is sealed plywood under the aquarium.
2. Measure the following heights from the underside of the floor panel. Mark the beam underside at 20 7/8 in (530.23 mm), lower track seat at 24 1/2 in (622.3 mm), land-deck top at 15 1/2 in (393.7 mm) and liner top at 20 3/4 in (527.05 mm). Buy and measure the Seapora 59211 Standard 50-gallon aquarium before the surround cuts. Its catalog size is 36 in (914.4 mm) × 18 in (457.2 mm) × 18 in (457.2 mm); that is a nominal reference, not the complete measured frame. The actual frame must fit within 36 1/4 in (920.75 mm) × 18 1/2 in (469.9 mm) × 19 1/8 in (485.78 mm).

Check before continuing: The compressed lining stack is recorded and the height strip carries the independent deck, bed, clamp and track datums.

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6. Measure the actual aquarium frame and rim

Parts: TANK — complete received aquarium frame; P01 floor; surrounding wood ledgers and collars

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Measure the complete received aquarium frame and rim on its maker-approved, continuous base support. Mark the enclosure floor and front datums on a separate measuring strip; transfer the actual rim height to the labelled loose surround pieces. The shell is not assembled yet. The reference front position is about 2 5/16 in (58.74 mm) behind the enclosure front, centred between the left support and divider. Use full-size templates to check the planned bay. Keep collars 1/8 in (3.18 mm) above the measured rim and 1/8 in (3.18 mm) away from the frame. Collars bear on wood ledgers, never on the glass or rim. Recheck these measurements during the actual empty-tank trial after assembly.

Check before continuing: The measured aquarium fits the bay dimensions, and all gauges agree with the fitting worksheet. No glass has been ordered.

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7. Cut the plywood blanks

Parts: P01/P02 — floor and roof; P03L/P03R — walls; P04 — back; RB1/RB2/RB3 — front layers

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use all six numbered PLY layouts. Each sheet needs at least 96 3/8 in (2447.93 mm) × 48 3/8 in (1228.73 mm) usable stock for these rough blanks, trim and 1/8 in (3.18 mm) kerf. Measure every sheet; exact nominal 48 in (1219.2 mm) × 96 in (2438.4 mm) stock is insufficient. Finish floor and roof at 96 in (2438.4 mm) × 24 in (609.6 mm) with widthwise grain; never shrink the shell to fit short stock.
2. At the reference 45/64 in (17.86 mm) plywood gauge, sides finish at 24 in (609.6 mm) × 46 19/32 in (1183.48 mm); back 94 19/32 in (2402.68 mm) × 46 19/32 in (1183.48 mm); three front layers 94 19/32 in (2402.68 mm) × 23 51/64 in (604.44 mm). Fit paired parts against the actual floor/roof offcuts. Coordinate every changed dimension when received gauge differs.

Check before continuing: Each plywood blank matches its own cut size and label; paired walls and the three uncut front blanks match.

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8. Label paired parts and fit the measured stock

Parts: DIV — divider; DECK — land deck; CAP1/CAP2 — doors; CHB1/CHB2 — hinge strips; named surround blanks in the cut list

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut the deck, divider, cabinet doors, hinge strips and tank surround from their numbered rough allocations. Cabinet door cores finish at 23 15/16 in (608.01 mm) × 13 3/8 in (339.73 mm). Tank-related pieces are starting references: fit their final positions and collars to the received aquarium with 1/8 in (3.18 mm) clearance.
2. Sizes marked “about” are rounded to the nearest 1/16 in (1.59 mm) for easy marking. Trim these starting sizes to make snug, fully supported joints. Keep the cut on the waste side of the line, test the actual mating parts and trim gradually for full contact. Use one unit system for a cut; do not switch between rounded inch and millimetre values.

Check before continuing: The divider, deck, doors, strips and surround blanks are labelled and fitted to the recorded material gauges; final openings are still to be cut.

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9. Cut the tank and cabinet front openings

Parts: RB1/RB2/RB3 — three matching front layers

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Transfer openings to all three front layers from the assembly datums. Tank opening is 39 19/64 in (998.14 mm) wide and 20 11/64 in (512.37 mm) high from each layer’s lower-left corner. Cabinet openings are 21 in (533.4 mm) × 10 1/2 in (266.7 mm), starting at assembly X = 44 1/2 in (1130.3 mm) and 70 1/2 in (1790.7 mm), Z = 2 1/4 in (57.15 mm). From each layer’s own left/bottom edges subtract the measured plywood gauge. Clamp matching layers and support each waste piece; preserve the top beam and all webs.

Check before continuing: All three front layers have matching tank notches and cabinet openings, with the top beam and webs intact.

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10. Mark four roof openings and preserve webs

Parts: P02 — removable roof

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On the roof, mark four 18 in (457.2 mm) × 16 in (406.4 mm) openings. Their front edges are 4 in (101.6 mm) from the front; left edges are 6 in (152.4 mm), 28 in (711.2 mm), 50 in (1270 mm) and 72 in (1828.8 mm) from the left. Keep all three 4 in (101.6 mm) webs intact for the roof ribs.

Check before continuing: Four roof openings are marked with the full outer borders and three rib webs preserved; no cut has started.

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11. Mark both raised side vents

Parts: P03L/P03R — left and right walls

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On each side, mark a 16 in (406.4 mm) × 4 in (101.6 mm) vent starting 4 in (101.6 mm) behind the front edge. The vent bottom must sit 25 1/2 in (647.7 mm) above the floor underside when assembled. Stand the loose side on a floor offcut and transfer that height; it is about 24 13/16 in (630.24 mm) from the side panel’s bottom with the reference plywood. Keep both vents above the aquarium rim and land bed.

Check before continuing: Both vent rectangles match the stated wall datums and sit above the track seat; roof and wall marks are ready for the supported cuts.

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12. Cut supported openings and inspect borders

Parts: P02 — Removable roof; P03L — L wall; P03R — R wall

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Drill starter holes entirely inside the waste. Cut with a guided router or supported jigsaw; do not cross the marked corner lines. Ease sharp reveals and remove every splinter.
2. Use a marked 1 in (25.4 mm)-wide capture-footprint template over each waste-side margin. Confirm mesh edges will lie beneath the captures and every fastener will land on solid wood. Trial the actual strips after they are made in the following stock and pocket operations. Leave the rest of the roof solid; equipment penetrations require their own later fitting.

Check before continuing: Both side vents sit above the lower track seat; all roof borders and all three rib webs remain intact.

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13. Prepare the safe wide frame and strip stock

Parts: F0/F1 — frame layers; V/RT — screen captures; LC — liner clamps; separate trial board

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the numbered PINE-FRAME, PINE-THIN and PINE-TRIAL layouts. They allocate six boards including a separate trial board. Label each named piece; do not reuse the old five-board numbering.
2. Rip frame strips to 3 1/2 in (88.9 mm) from guarded, safely held wide stock. Keep separate F0 and F1 layers and use the exact rough lengths, trim and 1/8 in (3.18 mm) kerf in the new layouts.
3. Plane safe full-width stock to 3/8 in (9.53 mm) before routing capture rebates or ripping the narrow screen and liner strips. Follow machine minimum feed lengths; never feed loose short strips into a planer.
4. Revised capture strips are 1 in (25.4 mm) wide with a measured crossing-depth rebate and separate outer bearing land. The next pocket operation gives the trial. Liner clamps remain their own 1/2 in (12.7 mm)-wide profile; do not rout screen pockets into them.

Check before continuing: Wide stock is correctly prepared and labelled for its frame, capture and liner-strip uses; the trial board is reserved.

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14. Cut and dress the solid supports

Parts: The 35 named solid supports, posts, ribs and ledgers in the SOLID stock layouts

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut to length eleven solid 2 × 2 boards for all 35 solid members: bottom wood supports, rear uprights, the four front posts, upper wood supports, roof ribs, the deck ledgers, the divider wood support, the collar ledgers and the tank kick rail. Use their actual full section; these are not laminated strips. Include the new solid rear divider receiver DBV and front collar ledger LEDF.
2. Lightly ease exposed corners and especially the wood supports beneath the liner. Keep joint faces square and bare. Label the underside of each roof capture so it returns to its own holes.

Check before continuing: All 35 solid members match their labels and cuts, bearing faces stay square, and no cracked or knot-weakened support is used.

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15. Trial and machine the screen pockets

Parts: Trial board; eight V and sixteen RT capture strips; mesh offcut

Tools / setup: Caliper, guarded router, fixed guide, clamps, wide sacrificial stock, eye/hearing/dust protection

1. Measure the largest welded-wire crossing and the actual cured film on both bearing faces. Reference wire is 0.041 in (1.04 mm), crossing 0.082 in (2.08 mm), and two 0.003 in (0.08 mm) films give a 0.088 in (2.24 mm) pocket. These are model inputs, not delivered tolerances.
2. On a wide clamped trial blank, use a guided router and shallow passes to form the rebate: a shallow edge pocket. Leave a full outer bearing land. The nominal 1/2 in (12.7 mm) land loses 0.006 in (0.15 mm) to perimeter fitting relief, leaving 0.494 in (12.55 mm). It must sit flat while all wire ends remain buried.
3. Do not exceed 1/8 in (3.18 mm) pocket depth without redesign. Trial with the received mesh and finish, then machine safely wide blanks before final ripping/crosscutting. Record depths and labels on all twenty-four capture strips.

Check before continuing: Pocket fits the actual crossing; lands sit flat and wire cannot peel or rattle.

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16. Laminate the front and staggered frame

Parts: RB1/RB2/RB3 — front laminate; F0L/F1L, F0R/F1R and F0T/F1T — frame layers

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Dry-stack RB1, RB2 and RB3 face to face, flush at their top and ends, with the notch and both openings aligned. The stack is three plywood thicknesses deep. Dry-lay the front frame above them: outer layer jambs run full height, inner layer header runs full width.
2. Spread Titebond III on the two front-layer bond interfaces and between the two frame layers. Keep a consistent film across bare wood; use padded flat clamping pads and enough clamps to close the joints without bowing the long members.
3. Compare both frame diagonals and check the track-bearing faces with a straightedge. Wipe away squeeze-out before it hardens. Do not glue the frame to the laminated front yet; these remain separate assemblies for finishing.
4. Follow the glue label for temperature and clamping. Leave these unstressed glue-ups for at least 24 hours before drilling or loading, extending the wait when the manufacturer requires it.

Check before continuing: The laminated front is flat; its 3 5/8 in (92.08 mm) beam over the tank bay is straight, and the 1 1/2 in (38.1 mm) deep frame has staggered, closed joints.

Required wait: Glue cure: at least 24 hours; follow the received label

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17. Trial the matched steel and glass system

Parts: Received KV993/995/997/999 sample, exact-thickness disposable gauge, anti-lift sample and bond offcuts

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Make a rigid full-size bench fixture for the reference 87 19/32 in (2224.88 mm) × 19 19/64 in (490.14 mm) opening. Hold the loose frame pieces square in that fixture; the installed frame comes later. Use a smooth disposable panel measured to the accepted 0.2362 in (6 mm) glazing thickness. Nominal 1/4 in (6.35 mm) material is thicker and must not establish fit. This gauge is never a substitute door. Repeat the trial in the assembled opening during track alignment, and use final measured dimensions before releasing the glass order.
2. Assemble offcuts of the actual 999 lower track, 997 carrier, 995 shoe and 993 upper channel around the measured 0.2362 in (6 mm) disposable gauge. Keep the matched family throughout. Model envelopes do not certify the proprietary internal profiles.
3. The manufacturer deducts 1 1/4 in (31.75 mm) from the distance between the OUTSIDE top of the upper channel and OUTSIDE bottom of the lower track. Include the actual bond beds when locating those faces. Confirm rolling, upper engagement, lift-out and the 1 in (25.4 mm) closed overlap with the sample. Also make a steel-offcut-to-bare-wood bond sample under the reassemble and measure for the glass doors operation’s preparation and cure; reject peeling or failed adhesion before committing the tracks.

Check before continuing: The matched sample rolls and lifts out with retention removed. The cured bond sample holds without peeling. No glass has been ordered.

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18. Trial folds and the empty aquarium transfer

Parts: LINER and UNDERLAY samples, five post outlines and the empty received TANK

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fold a liner offcut around an eased post and into a corner; keep folds uncut. Reserve at least 1/8 in (3.18 mm) at walls and posts, increasing the allowance for the actual folded stack.
2. Keep the empty received aquarium on its maker-approved continuous support. Place full-size, non-loadbearing clearance templates around it to check the planned floor, beam, divider and collar positions. Check the complete transport and removal route with the qualified handling team. Templates do not support the aquarium. Perform the actual shell transfer trial after the bay and removable surround have been fabricated.

Check before continuing: Sample folds fit without stretching; full-size templates and the handling plan establish clearance for the later supported empty-aquarium trial.

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19. Position and predrill the bottom supports

Parts: P01 — Floor; CLB — L bottom cleat; CRB — R bottom cleat; CF — Front floor cleat; CB — Back floor cleat; CB2 — Back floor cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place P01 on a flat sacrificial board. Mark the left and right wood supports one actual plywood thickness in from the floor edges, starting behind the three-layer front. Fit CF only on the land side, from the divider line at about 42 3/16 in (1071.56 mm) to the right wood support; the tank bay has no front floor wood support so the empty aquarium can be lifted and transferred out. Fit CB behind the tank bay and CB2 behind the land side, leaving a gap for the divider.
2. Clamp each wood support. Transfer the attach the bottom wood supports operation stations through the floor: #8 clearance holes are 11/64 in (4.37 mm) through P01 only; start 7/64 in (2.78 mm) pilots into pine and confirm grip on an offcut. Set a stop so no drill or screw can emerge.

Check before continuing: The five bottom supports are correctly located and clamped; clearance holes pass through the floor only and stopped receiver pilots cannot emerge.

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20. Glue and fasten the floor from underneath

Parts: P01 — Floor; CLB — L bottom cleat; CRB — R bottom cleat; CF — Front floor cleat; CB — Back floor cleat; CB2 — Back floor cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply Titebond III only to the floor/wood support bond faces. Drive the #8 × 1 1/4 in (31.75 mm) screws from below, leaving their heads flush with the floor underside. Wipe all squeeze-out and keep the four corner beds smooth.
2. Check the tank bay floor is flat and clean: no glue, screw head or lump where the aquarium frame will bear. Let the floor assembly cure flat and unstressed.

Check before continuing: The floor underside sits flat with no projecting head; the tank bay floor is flat and free of wood supports.

Required wait: Do not stress glued wood supports for at least 24 hours

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21. Fit walls and upper supports

Parts: P03L — L wall; P03R — R wall; CLU — L rear upright; CRU — R rear upright; CLT — L upper cleat; CRT — R upper cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Clamp CLU and CLT to the inside of the left wall; repeat with CRU and CRT on the right. Upper wood supports end at the back-panel face and start 1 1/2 in (38.1 mm) behind the front. The rear uprights fit between lower and upper wood supports.
2. Stand each wall on P01, flush with its outer edge and front. Clamp it to the bottom wood support. Use a helper while the box is open.
3. Transfer the listed stations through each wall into the matching solid receiver. Drill the #8 clearance through the plywood, then a stopped pilot into pine. Keep the rear-upright back screws offset from the side screws as shown in the station schedule.
4. Fasten with #8 × 1 1/4 in (31.75 mm) screws, tightening by hand for the last turn. These wall joints stay dry during fitting so the panels can be removed for finishing.

Check before continuing: Walls are upright and parallel; all screw points terminate in solid wood supports, and no screw projects into the room.

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22. Close and square the back

Parts: P04 — Back; CT — Back upper cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit P04 between the side panels, resting on the floor with its outside face flush to the side-panel rear edges. Clamp to CB, CT and both rear uprights.
2. Compare the two diagonals across the front and across the back. Adjust until each pair differs by no more than 1/16 in (1.59 mm). Recheck on the final supporting surface if it differs from the bench.
3. Drill clearance through P04 and stopped pilots into the named receivers at the close and square the back operation stations. Use the offset upright positions so a back screw does not meet a side screw.
4. Fit the #8 × 1 1/4 in (31.75 mm) screws and check that the full back edge sits flush. Do not pull a twisted box square by overdriving a screw.

Check before continuing: The shell remains square without clamp pressure; the back and both walls bear on the floor.

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23. Add the three rear uprights

Parts: CM1 — Intermediate back upright; CM2 — Intermediate back upright; CM3 — Intermediate back upright

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place CM1, CM2 and CM3 against the inside of the back at centres 24 in (609.6 mm), 48 in (1219.2 mm) and 72 in (1828.8 mm) from the left outside face. CM1 fits between CB and CT; CM2 and CM3 fit between CB2 and CT ; each upright is about 43 5/8 in (1108.08 mm) long in the reference shell.
2. Clamp each upright square with its bottom bearing fully on its assigned lower wood support. Transfer the add the intermediate rear supports operation stations through P04. Drill #8 clearance through the plywood and stopped 7/64 in (2.78 mm) starting pilots into the solid pine.
3. Fit the listed #8 × 1 1/4 in (31.75 mm) screws from the back. Tighten evenly by hand, keeping the back flat and the upper wood support level. Confirm all points remain buried.
4. Check all three intermediate uprights and both rear corner uprights bear on their lower wood supports. Leave the four front posts loose until the laminated front is seated in the next step.

Check before continuing: Five rear uprights are square and secure; no screw point or sharp corner meets the future liner or aquarium.

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24. Seat and screw the laminated front

Parts: RB1/RB2/RB3 — laminated front; P01 — floor; P03L/P03R — walls

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Seat the cured three-ply front on P01 with its front face flush to the floor front. Over the tank bay it is a beam 3 5/8 in (92.08 mm) deep whose underside sits 20 7/8 in (530.23 mm) above the floor underside; over the land side it runs down to the floor. Check the top at 24 1/2 in (622.3 mm) with a long straightedge.
2. Fasten the laminate ends through the sides and stitch the plies together with the scheduled #8 × 2 in (50.8 mm) screws from the front. From inside the land side, fit the rear-facing 2 in (50.8 mm) screws through CF into RB3, offset so opposing screws cannot meet.

Check before continuing: The three-layer front is square, flat, fully seated and secured at the current stations; front-post work is next.

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25. Position and secure all four front posts

Parts: CFL, CF1, CF2, CFR — four front posts; CLB, P01 and CF — their separate bearing supports

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Stand CFL, CF1, CF2 and CFR behind the laminated front with their front faces against the back of the three-layer front. CFL stands on the left bottom wood support at the tank bay's left edge; CF1 stands on the floor at the tank bay's right edge, 40 in (1016 mm) from the left; CF2 and CFR stand on CF on the land side. Clamp all four tightly to the laminate.
2. Transfer the side screw stations through the left and right walls into CFL and CFR and fit the listed #8 × 1 1/4 in (31.75 mm) screws. Keep CF1 and CF2 clamped; their through-bolts make the front connection.

Check before continuing: All four posts bear on their named supports and meet the laminate without gaps; clamps remain until connections are complete.

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26. Trial the flush connection and nut recess

Parts: Matching three-layer plywood and post offcuts; one complete flat-head screw, washer and locknut stack

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Trial Bolt Depot 24910, 316 stainless 1/4-20 × 3 1/2 in (88.9 mm) flat-head screw with 16019 washer and 16008 nylon locknut in a held scrap stack matching three plywood layers plus a 1 1/2 in (38.1 mm) post. Head length includes the flat head. Trial the actual 82-degree seat and 5/32 in (3.97 mm) hex drive; no carriage bolt or outside nut remains.
2. From the inside post face, trial a stopped 1 in (25.4 mm) diameter × 5/8 in (15.88 mm) deep flat-bottom nut recess. Leave 7/8 in (22.23 mm) post thickness at the washer seat. Confirm an actual socket no wider than 7/8 in (22.23 mm) can reach the complete nut. Keep actual washer thickness at most 1/16 in (1.59 mm), at least two full threads beyond the nylon, and at least 1/16 in (1.59 mm) between the tail and the post face. No connection capacity or torque is assigned.

Check before continuing: The scrap stack accepts the full washer/locknut, two exposed threads, required tail cover and actual socket without split or crushed wood.

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27. Bore and fit nineteen flush connections

Parts: RB1/RB2/RB3, four front posts and nineteen complete recessed connections at the numbered stations

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Follow the revised nineteen stations: CFL one beam connection; CF1, CF2 and CFR six each. Clamp the laminate against each post. Bore square 9/32 in (7.14 mm) clearance through the stack with backing, then the stopped rear nut recess. Countersink the exterior only to seat the received flat head flush on bare wood. Keep shifted stations and every surrounding screw clear.
2. Insert the flat-head screw from the front. Fit washer and full locknut inside the rear post recess, before the liner or inaccessible finish assemblies. Tighten by hand only to close the joint; reject galling, crushed wood, partial engagement or an exposed tail. Never omit the washer or deepen a recess to force a wrong stack.
3. Check all nineteen connections, square front and clear cabinet openings. Keep 0.55 in (13.97 mm) veneer access around exposed flat heads. The removable second hinge strip covers three drives and must come off as a supported door/hinge/strip unit for service. Use loose protective underlay pads over recessed nuts beneath liner folds; these retainer bolts never pierce the membrane.

Check before continuing: All nineteen heads sit flush, nuts fully engage, tails stay recessed and the front remains square; access footprints are recorded.

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28. Fit the divider, hose opening and rear receiver

Parts: DIV — Tank-bay divider; DVB — Divider floor cleat; DBV — Solid rear divider receiver; CF1 — Front retainer post

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Position DIV with its tank-side face at assembly X = 41 1/2 in (1054.1 mm), front at Y = 2 7/64 in (53.58 mm) and bottom at Z = 45/64 in (17.86 mm) in this reference gauge. Keep its 1 3/4 in (44.45 mm) × 2 in (50.8 mm) hose opening at Y = 18 in (457.2 mm), Z = 9 1/2 in (241.3 mm). The front posts are already fixed: fit DIV to CF1 and add its floor cleat DVB only after the front-to-post screw is accessible and installed. Fit DBV on the land side, bearing on CB2 and aligned with the marked position of the later DLB1 ledger. Use the exact staggered front, back and divider screw stations; do not drive a screw into the plywood edge or hose opening.

Check before continuing: DIV has full solid receivers, an unobstructed hose opening and buried screw points; no edge screw or crossing screw remains.

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29. Fit the ledgers and raised land deck

Parts: DECK, DLF1, DLF2, DLB1, DLB2, DLB3, DLL, DLR; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit DLF1 and DLF2 against RB3 before fitting the left side ledger DLL, so the DLF1 end screw remains accessible. Fit the three rear ledgers, DLL and DLR with tops at 14 51/64 in (375.84 mm). Lay the notched DECK on all seven ledgers with its bare top at 15 1/2 in (393.7 mm). Fit every scheduled deck screw into its named ledger; no edge is left floating.

Check before continuing: Every deck edge and all seven ledgers bear fully; the top is level at the specified reference datum and all five notches clear the posts.

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30. Fit the tank-surround ledgers and fascia

Parts: LEDL — Collar ledger; LEDR — Collar ledger; LEDB1 — Collar ledger; LEDB2 — Collar ledger; LEDF — Front collar ledger on removable fascia; FAS — Removable aquarium-front fascia

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit LEDL, LEDR, LEDB1 and LEDB2 from the received aquarium rim with 1/8 in (3.18 mm) vertical clearance; reference ledger top is 18 53/64 in (478.23 mm). Keep actual receivers and staggered fastener paths. FAS is 40 51/64 in (1036.24 mm) wide, with top Z = 21 7/8 in (555.63 mm). The revised LEDF is 37 35/64 in (953.69 mm) long; centre it on the original outline, leaving 1/8 in (3.18 mm) trimmed at each end, and attach it to FAS on the bench. Four upper FAS screws at Z = 21 3/8 in (542.93 mm) enter RB1. No glue joins this unit to the shell.

Check before continuing: The collar ledgers and removable fascia fit the measured rim datum with the required clearance; the four upper fascia drives stay accessible.

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31. Trial removable collars and the kick rail

Parts: COLL — Removable rim collar; COLR — Removable rim collar; COLB — Removable rim collar; COLF — Removable front rim collar; FAS — Removable aquarium-front fascia; LEDF — Front collar ledger on removable fascia; KR — Removable tank kick rail

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Transfer the recorded received-frame dimensions to rim templates, including 1/8 in (3.18 mm) horizontal and vertical clearance. Keep the aquarium removed before any cutting, drilling or sanding. Use the templates to fit all four collars and the kick rail.
2. LEDF and COLF are each shortened 1/8 in (3.18 mm) at BOTH ends from their source outlines for finished withdrawal clearance; retain the original screw stations. On the supported, removed FAS/LEDF unit, fasten COLF to LEDF with four screws. Attach this complete unit using the four upper FAS screws. The installed beam blocks a straight driver above COLF, so COLF must remain attached to its unit for removal. COLL and COLR use four screws each and COLB uses six over their ledgers. Fit KR with four screws through its stopped access bores. Keep every piece removable.
3. After all fabrication, remove collars, the FAS/LEDF/COLF unit and KR. Clear every burr and chip from the bay and the aquarium support. With qualified handling help and continuous support, trial-transfer the empty aquarium into place without dragging it. Trial the collars and kick rail without cutting or drilling near the tank. Confirm the rim clearance and complete removal path, then remove the aquarium and store it safely for finishing.

Check before continuing: The front collar withdraws with its unit, other collars lift separately, and all four kick-rail screw heads can be reached.

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32. Fit cabinet cores and solid hinge strips

Parts: CAP1 — Cabinet 1 hinged equipment-access door; CAP2 — Cabinet 2 hinged equipment-access door; CHB1 — Cabinet 1 hinge mounting strip; CHB2 — Cabinet 2 hinge mounting strip

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut two CHB mounting strips, 13 1/2 in (342.9 mm) × 1 1/2 in (38.1 mm), from the door plywood. Each revised door is 23 15/16 in (608.01 mm) wide × 13 3/8 in (339.73 mm) high. Keep the original right and top positions, leaving a 3/16 in (4.76 mm) bare hinge-side gap and bottom Z = 7/8 in (22.23 mm). This provides veneer clearance without shifting hinge-hole or knob centres. Clamp faces flush and trial full finished samples.
2. Do not cut the old three deep nut pockets into CHB2. The revised bolts have flush front heads; the strip stays solid and removable. Confirm it rests flat without pressing on a head. Never glue this strip to the front or bridge its outline with veneer.

Check before continuing: Door hinge-side and bottom gaps accept the full finished stack; strips are solid, flat and removable.

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33. Fasten the removable hinge mounting strips

Parts: CHB1 — Cabinet 1 hinge mounting strip; CHB2 — Cabinet 2 hinge mounting strip; RB1 — Laminated front beam and land lip

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fasten each mounting strip to the solid front with three #8 × 1 1/4 in (31.75 mm) screws. Put this screw line 3/8 in (9.53 mm) from the strip’s left edge, clear of the hinge. Mark the screws 3/4 in (19.05 mm), 5 1/4 in (133.35 mm) and 12 3/4 in (323.85 mm) from the strip’s bottom. Drill clearance holes through the strip and pilots into the front; keep clear of the existing bolts and screws.

Check before continuing: Three accessible screws secure each strip without meeting a retainer connection; both strips can be removed independently.

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34. Transfer hinge holes and hang supported doors

Parts: CAP1, CAP2, CHB1, CHB2, CH1F, CH1D, CH2F, CH2D; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Set each 12 in (304.8 mm) National N265-363 hinge with its lower end at assembly Z = 1 1/2 in (38.1 mm) and upper end at Z = 13 1/2 in (342.9 mm); do not recenter it on the trimmed door. Its barrel faces outward. Transfer all twelve holes from the received hinge: six per leaf. Use separate #5 × 5/8 in (15.88 mm) flat-head screws, not the supplied longer screws. Trial the stopped pilot and complete countersink in the actual plywood so no tip emerges. Mask veneer beneath both leaves, including where a leaf crosses the door or strip edge. Support the door throughout fitting.

Check before continuing: Every received hinge hole is used; stopped screws remain buried, the barrel is free and each supported door swings without rubbing.

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35. Fit the magnetic catches and recessed strikes

Parts: CAP1 — Cabinet 1 hinged equipment-access door; CAP2 — Cabinet 2 hinged equipment-access door; CBMAG1 — Cabinet 1 magnetic catch; CBMAG2 — Cabinet 2 magnetic catch; CS1 — Cabinet 1 magnetic strike; CS2 — Cabinet 2 magnetic strike

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Mount one magnetic catch below each opening’s top near the right end. Keep its body-to-wood bearing footprint free of added reveal veneer, and set its face at the original front closing plane. Use the supplied 1/2 in (12.7 mm) truss-head screws. Transfer the strike to the door BACK and recess only to its measured thickness; the strike face finishes at the original back plane. Fit its supplied 1/2 in (12.7 mm) flat-head screw after a stopped-depth trial. Adjust until the finished door closes freely and the magnet meets the strike.

Check before continuing: Each catch meets its recessed strike at the original closing plane without forcing the door; reveal veneer does not sit under the body.

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36. Fit cabinet knobs on bare bearing seats

Parts: CAP1 — Cabinet 1 hinged equipment-access door; CAP2 — Cabinet 2 hinged equipment-access door; CK1 — Cabinet 1 pull knob; CK2 — Cabinet 2 pull knob

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Keep each knob at its original assembly centre: X = 64 1/4 in (1631.95 mm) or 90 1/4 in (2292.35 mm), Z = 7 1/2 in (190.5 mm). That is 2 3/4 in (69.85 mm) from the revised door’s right edge and 6 5/8 in (168.28 mm) from its bottom. Drill a backed 3/16 in (4.76 mm) through-hole and trial the supplied #8-32 × 1 in (25.4 mm) screw. Stop veneer at the traced knob-base footprint so its bare bearing plane stays unchanged; confirm actual thread engagement without bottoming.

Check before continuing: Both knobs seat firmly on their traced bearing footprints; machine screws engage without bottoming or protruding.

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37. Test both cabinet swings and equipment access

Parts: CAP1/CAP2 — doors; CHB1/CHB2 — removable hinge strips; hinges, catches, knobs and finish samples

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Open each door at least 90° and check both together. They must clear the hinge strips, front bolts, support below and each other. Reserve 26 in (660.4 mm) in front for door swing and handling equipment. Confirm the actual filter, hoses and lids can be reached and removed. These magnetic catches close equipment doors; they are not animal-containment locks. At the later finishing operation, remove the doors and hardware; refit only after the specified coating and sealant cure holds. Repeat this check with the actual finished surfaces.

Check before continuing: Both supported doors clear through at least 90 degrees with full-thickness finish samples at the relevant gaps; closing and equipment access are recorded for rechecking after finishing.

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38. Fit the upper jambs and header

Parts: F0L — L jamb layer; F1L — L jamb layer; F0R — R jamb layer; F1R — R jamb layer; F0T — Header layer; F1T — Header layer

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Set the laminated front frame on the lower track seat. Align its front face with the laminate and sides. Both jambs must bear fully on the laminate; do not suspend them on screws.
2. Clamp the frame square. Drill #8 clearance through the side panels into stopped pilots in the jamb ends at the scheduled heights. Fit #8 × 2 in (50.8 mm) screws.
3. Measure the clear opening at the top, middle and bottom and the clear height at three positions. Reference width is about 87 5/8 in (2225.68 mm) and height is about 19 5/16 in (490.54 mm). Record the smallest values and both diagonals.
4. Lay a straightedge beneath the header and over the beam. Correct any bow now. The detachable roof will later screw into the header and wood supports, further closing the box.

Check before continuing: The opening is square within 1/16 in (1.59 mm) and its upper/lower track faces are straight and parallel.

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39. Inspect receivers, pilots and flush heads

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Compare the assembled shell with the part list and inspect every joint from both sides. Use the fastener-stations download to check that no receiver, through-member or screw is missing.
2. Make pilot tests in matching offcuts. The starting pilots are 7/64 in (2.78 mm) for #8, 3/32 in (2.38 mm) for #6 and 1/16 in (1.59 mm) for #4. Adjust for the actual wood and screw root; a split or spinning test means the setup is wrong.
3. Set the clearance depth separately from the receiver pilot. Use 11/64 in (4.37 mm), 9/64 in (3.57 mm) and 1/8 in (3.18 mm) starting clearance bits for #8, #6 and #4 respectively. Confirm head shape in a scrap countersink.
4. Keep at least 1/16 in (1.59 mm) unpierced wood beyond a screw point. Do not substitute a longer screw to repair a stripped hole; repair or replace its receiver and repeat the trial.

Check before continuing: No point, burr, split, hollow screw path or proud floor screw remains.

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40. Cut and deburr all six mesh blanks

Parts: ML — L ventilation mesh; MR — R ventilation mesh; MTL — Roof mesh; MTM — Roof mesh; MTN — Roof mesh; MTR — Roof mesh

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut four roof pieces 19 in (482.6 mm) × 17 in (431.8 mm), and two side pieces 17 in (431.8 mm) × 5 in (127 mm), from the hardware-cloth roll. Wear eye protection and cut-resistant gloves while handling the cut edges.
2. Remove projecting wire ends and burrs. Keep a minimum 1/2 in (12.7 mm) mesh margin beyond each opening, fully under the capture strips. Do not leave a sharp wire end exposed to the room.
3. Check the mesh opening against the future occupant and feeder plan. This 1/2 in (12.7 mm) construction mesh will require a securely retained finer barrier for many occupants; do not treat it as universal animal containment.
4. Label the four roof pieces and two side pieces. Store them flat until their capture strips are ready.

Check before continuing: All edges are smooth and will be enclosed; none of the six pieces is stretched, rusted or damaged.

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41. Capture the side screens on solid lands

Parts: ML, MR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Centre ML/MR on their own vent openings and fit the widened one-inch captures with routed pockets facing the wire. Full outer lands bear flat; all cut wire and welded crossings remain enclosed.
2. Transfer the revised outer-land stations. Drill clearance through each strip and stopped pilots into the wall; never drill a wire crossing. Fit #6 × 1 in (25.4 mm) screws flush without crushing a land. Reference pockets are 0.088 in (2.24 mm), subject to the actual crossing/finish trial.
3. Drive the #6 × 1 in (25.4 mm) screws until the strips hold the mesh firmly. With 3/8 in (9.53 mm) captures and the reference plywood, the points must stay buried; verify from inside after every group.
4. Run a cloth along the entire interior reveal and gently press the mesh perimeter. Fix any snag or loose edge. Remove the assemblies again during the finishing step, preserving the labels.

Check before continuing: There is no accessible cut wire or loose mesh edge; the opening remains above the fill line.

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42. Assemble the removable screened roof

Parts: P02, CR1, CR2, CR3, MTL, MTM, MTN, MTR, RTLF, RTLA, RTMF, RTMA, RTNF, RTNA, RTRF, RTRA, RTLL, RTLR, RTML, RTMR, RTNL, RTNR, RTRL, RTRR; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place the roof underside up on padded supports. Fit CR1, CR2 and CR3 between the front frame position and rear upper wood support, with centres 26 in (660.4 mm), 48 in (1219.2 mm) and 70 in (1778 mm) from the left outside edge. All three ribs lie beneath the solid webs between openings. Transfer their top-down #8 screw stations through the roof into each rib.
2. Centre the four 19 in (482.6 mm) × 17 in (431.8 mm) mesh blanks beneath the four 18 in (457.2 mm) × 16 in (406.4 mm) roof openings. Fit sixteen one-inch captures with measured rebates facing the wire. Use current solid-land stations and stopped roof pilots; keep all cut wire enclosed.
3. Turn the roof with a helper and check every point remains beneath the outer face. All three ribs sit between the openings and end against the rear wood support; the vent borders stay fully supported.
4. Dry-seat the roof and transfer its final screw holes. Leave them unfastened until access work is complete. The roof and mesh are not shelves. Inside or screen-top equipment is permitted only where its instructions allow it and qualified framing or another support carries the complete fixture weight.

Check before continuing: The roof sits flat, its wire edges are enclosed and it can lift off without catching the frame.

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43. Cut accepted profiles and fit the jamb relief

Parts: TRACK-B, TRACK-T, JAMBL, JAMBR, STOPLF, STOPLB, STOPRF, STOPRB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. After H01 acceptance, cut matching profiles from the numbered layouts: one 144 in (3657.6 mm) bar each of KV993, KV995, KV997 and KV999. Upper/lower track reference length 87 11/32 in (2218.53 mm), jambs 17 39/64 in (447.28 mm), shoes 44.1689 in (1121.89 mm), carriers 65.7533 in (1670.13 mm). Use protected vise jaws, square cuts and deburred ends; retain every required carrier ball. No track joints.
2. Fit the right-jamb central-divider relief only in its scheduled interval above the retainer. Preserve backing web and outer legs. Trial the received ratchet clip, cushion and every lane. Dry-fit four reference 1/32 in (0.79 mm) bond beds on bare wood; no veneer or polyurethane beneath steel bonds and no screws through rolling tracks.

Check before continuing: Accepted profiles have square, deburred cuts; the relieved divider clears the actual lock while its backing and outer legs remain intact.

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44. Align tracks and trial plain jamb cushions

Parts: TRACK-B, TRACK-T, JAMBL, JAMBR, STOPLF, STOPLB, STOPRF, STOPRB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Align upper/lower lanes straight, parallel and vertically matched using actual profile centres and a disposable gauge. Temporarily brace the sample. Reference profiles do not prove proprietary internal raceways or ball seating.
2. Trial four plain neoprene cushions ending between the horizontal tracks. Accepted contact bonds replace old screw tabs. A 0.003 in (0.08 mm) cured bond film is only a reference; measure it before glass sizing. Complete track and cushion bonds after finishing, with all required cure waits.

Check before continuing: Matched lanes are straight and the gauge rolls freely; track and cushion BOND footprints are marked, with no old cushion screw tabs.

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45. Predrill the eight removable anti-lift inserts

Parts: ALF1, ALF2, ALF3, ALF4, ALB1, ALB2, ALB3, ALB4, STOPLF, STOPLB, STOPRF, STOPRB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Trial eight smooth HDPE inserts in the received upper lanes around a seated disposable gauge. Machine wide stock to the required installed thickness, reference 11/32 in (8.73 mm), and preserve positive lower capture with at most 1/16 in (1.59 mm) glass lift. Purchased 1/2 in (12.7 mm) stock thickness is not the installed dimension.
2. Use four strips per lane with closed internal joints. The outside ends are shortened by 1/8 in (3.18 mm) only to clear the cured jamb cushions during lowering. Keep continuous restraint through all travel. The exact outer and middle rough/final lengths differ in the cut table.
3. Before coating, transfer two holes per strip with the disposable gauge removed. Fit flush #4 × 3/4 in (19.05 mm) heads, clearance through insert and upper web, and stopped header pilots. Trial the driver with the disposable gauge parked away; support loose strips while changing the gauge position. No screw tabs remain on the cushions.

Check before continuing: All sixteen insert screw paths have sound receivers and accessible drives; the disposable gauge proves the intended capture and removal sequence.

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46. Disassemble, sand and mask the wood

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Photograph the labeled dry fit, then dismantle for finishing. Support and remove cabinet door/hinge/strip assemblies, take off the FAS/LEDF/COLF unit, other collars and KR, and keep hardware indexed. Remove all nineteen retainer connections for recess inspection. Keep glued laminations and floor-cleat assemblies intact; no aquarium remains during sanding or coating.
2. Sand from 120 to 220 grit along the grain. Ease all liner-contact edges; vacuum dust and wipe with a clean lint-free cloth. Fill no structural defect with finish; replace damaged material.
3. Keep glass, carriers and mesh out of the finishing area. Mask every marked track-bond footprint to preserve clean bare wood. Keep the permanently glued assemblies intact; photograph the labelled dry fit.
4. Current coating allowance is 636.02 square feet (59.09 square metres), including all conservative wood faces, veneer, two additional aquarium-bay coats, trial and handling. Need 13 quart cans (0.946 L each), purchased in two-can packs. Recalculate any additional coats or balancing layers.

Check before continuing: Wood is clean and dry, the deck and tank bay edges are eased, and all fittings are labelled for reinstatement.

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47. Apply the accepted wood coating

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check the can is Varathane Triple Thick clear satin water-based polyurethane, manufacturer 284473. The selected Lowe’s pack contains two quart cans. Stir; do not shake. Follow the received label and use a quality synthetic-bristle brush.
2. Apply one uniform coat to the exposed wood faces, all edges and opening reveals. The manufacturer’s application range is 60–90°F (16–32°C) below 85% relative humidity (RH). Ventilate the work area and use the label’s protective equipment.

Check before continuing: The first coat covers its scheduled faces without runs or missed edges; the application time and conditions are recorded before further coats.

Required wait: Follow received application and recoat instructions; full cure follows the final coat.

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48. Apply two extra coats in the aquarium bay

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Keep removable wood pieces separated for coating; the picture places them together only to identify the splash faces. Give the tank bay two further coats after the first has dried: its floor, the lower walls, the back of the laminate over the bay, the divider's bay face, the collar ledgers and both faces and all edges of the four collars, fascia and front ledger. Splashes and spills land here. The coating resists splashes; it is not a waterproof membrane, so wipe up standing water.
2. If repair coverage is needed, follow the 220-grit intercoat preparation and recoat instructions; add its coat area to the quantity record and restart the final-coat cure clock. Inspect the dry film for missed end grain, runs, tackiness and damage.

Check before continuing: Both additional coats cover the scheduled splash faces after their recoat waits; the last coat time starts the full-cure record.

Required wait: Respect the received recoat intervals and restart the full-cure clock after the final coat.

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49. Record and complete the coating full cure

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Record the time and conditions of the final applied coat. Full cure is seven days at 70°F (21°C) and 50% relative humidity (RH) with ventilation; adverse conditions need longer under the manufacturer’s directions. Two-hour recoat and 48-hour light-use times are not full cure.

Check before continuing: The recorded full-cure period has passed under suitable conditions and every coated surface is intact.

Required wait: Full cure: seven days at 70°F (21°C), 50% relative humidity (RH); longer when required

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50. Approve the complete veneer sample

Parts: Veneer trial piece and complete finishing system

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the actual substrate, sealer, selected veneer/backer/PSA and topcoat on a spare piece. PSA means pressure-sensitive adhesive. Supplier instructions control cleaning, acclimation, application pressure and dwell; no unsupported dwell time is substituted.
2. Measure the whole cured layer. The reference is 0.0305 in (0.77 mm); maximum 0.046 in (1.17 mm) before this design must be recalculated. Confirm one-sided panel balance and inspect after the intended humidity, heat and cleaning exposure.
3. Keep metal and cushion-bond footprints bare. The sample must remain flat and well bonded, with no lifting corners, bubbles or coating damage. Record the supplier-approved wait and the completed result.

Check before continuing: Approved sample is flat, secure and within the coordinated stack limit.

Required wait: Complete supplier-confirmed acclimation and adhesive dwell plus the received topcoat full cure.

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51. Mask hidden cabinet and fascia mating planes

Parts: RB1, P03L front edge, CAP1/CAP2, CHB1/CHB2 and FAS

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Transfer the scheduled closed-door, mounting-strip and fascia footprints to the fixed front. Keep these covered mating areas free of added veneer; the closing planes must remain where the hardware was fitted. The narrow left-wall front edge under FAS has the same mask. Use the specified clearance border and trial the complete layer thickness.
2. Mask the actual hinge-leaf, knob-base and magnetic-catch bearing footprints. Include the tiny strip/door edge areas crossed by hinge leaves and the upper cabinet reveal beneath each catch body. Keep the hidden KR underside bare where it bears on P01. End vent-frame bands at the fitted butt joints. Mask the wall skin to the finished vent-frame outline plus a 1/64 in (0.4 mm) service seam, so its edge bands do not overlap the wall veneer. Veneer all exposed exterior surfaces on the separate parts; do not bridge service seams or put an extra layer between mating hardware and wood.

Check before continuing: Every traced bearing area matches the actual dry fit; closed pieces conceal the masks and still clear each other.

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52. Cut and apply the matching edge strips

Parts: All scheduled edge and reveal V-pieces

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the VENEER layouts and labeled V-pieces. Put grain along each scheduled grain axis. Cover the floor/roof edges, exposed wall edges, roof-opening reveals, vent lips and external capture edges before their broad faces.
2. Cut oversized blanks on a sacrificial board with a sharp knife and straightedge. Use repeated shallow passes; keep fingers behind the cut. Transfer actual traced bearing footprints before peeling backing.
3. Apply the accepted PSA system with the specified firm scraper/pressure. Support fibers while trimming flush, then ease edges lightly. Do not bend veneer around a sharp plywood edge or bridge a removable seam.

Check before continuing: Exposed plywood layers are covered; hardware seats and service seams remain usable.

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53. Veneer the complete outside faces

Parts: All face V-pieces; separate roof, body and captures

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply the scheduled roof top, floor underside, sides, back, front frame, retainer front and external capture faces. N15 faces fit their own sheet widths without a centre seam. Include cabinet doors, hinge strips, removable fascia and kick rail. Keep the scheduled hidden closing/bearing footprints beneath doors, strips and fascia masked on RB1; do not add veneer between mating wood faces. Stop at each service seam and traced hardware footprint; preserve the wider hinge-side and bottom door gaps. Face veneers cover the ends of their matching edge strips. Keep roof grain straight and widthwise, including the front edge.
2. Trace openings from the actual parts, cut from the supported side and preserve all margins. Keep separate skins on the removable roof and each capture. Do not cover an assembly screw or the bare track footprint.
3. Open the scheduled full-depth screw-head access holes with supported tooling after the dry trial. Heads remain flush on their original wood datum. Inspect all outside corners and reveals before the final topcoat.

Check before continuing: Uniform chosen species covers faces, roof and edges without blocking removal or rolling hardware.

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54. Topcoat veneer and finish the full cure

Parts: Finished exterior and coating record

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the supplier-approved topcoat on the accepted veneer system. Protect marked track, cushion-bond and bare bearing seats; keep all service holes clear. Record application conditions and final coat time.
2. The selected coating’s reference full cure is seven days at 70°F (21°C) and 50% relative humidity. Follow the received label if conditions require longer. Recoat/light-use times do not establish full cure.
3. Inspect for bubbles, lifted edges, runs, tackiness and warp. Repair using an approved method and restart the affected cure clock. Recheck total layer thickness and flatness before final assembly.

Check before continuing: All affected surfaces are fully cured, flat and intact.

Required wait: Seven-day reference full cure after the final coat; longer when actual conditions or the received label require.

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55. Reassemble the cured shell for sealing

Parts: Finished wood shell and nineteen stainless retainer connections; cabinet units, loose surround and metal tracks kept off

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Reassemble only the cured wood shell and nineteen stainless recessed retainer connections. Inspect bearing, thread engagement, tail cover and access before lining. Leave cabinet door/hinge units, catches, knobs and every steel track/profile removed during bay sealing and its full cure. The DAP sealant is not recommended on or near brass, zinc, iron or galvanized metals; keep direct sealant contact on the specified coated wood only. Keep the tank surround removable. Do not bond tracks until the following sealant operation and cure are complete.

Check before continuing: Cured shell is square and retainer stacks are correct; vulnerable metal fittings and removable surround remain off for sealing.

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56. Seal the fixed aquarium-bay splash joints

Parts: P01 — Floor; P03L — L wall; P04 — Back; DIV — Tank-bay divider; CFL — Front retainer post

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Stop until H14 records supplier acceptance of the final coated-wood and metal-proximity arrangement. Offcut curing alone does not close that hold.

1. Resolve H14 first: obtain supplier acceptance of DAP 00688 on the cured coating and at its final distance from metal fittings. Its technical sheet excludes use on or near brass, copper, zinc, iron and galvanized metal; removing fittings during cure alone does not satisfy this restriction. Trial the accepted product on fully cured coated offcuts. Apply a 1/4 in (6.35 mm) fillet only at the pictured fixed tank-bay floor/wall joints, post feet and vertical corners. The routing allowance is 18 feet (5.49 m) plus 20% loss: three 2.8 US fl oz (83 mL) tubes calculated; buy one six-pack. Keep removable surround seams and hose routes clear. Do not bond EPDM or alter the purchased aquarium seams.

Check before continuing: Only fixed coated-wood junctions receive the trial-approved fillet; removable seams and hose openings stay clear.

Required wait: Keep vulnerable metal hardware and the aquarium removed until the full cure and bond trial are accepted.

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57. Tool the sealant and prove its full cure

Parts: P01, P03L, P04, DIV, CAP1, CAP2, CHB1, CHB2; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Tool short sections before skinning, targeting five minutes, and remove masks. Ventilate and follow received protective-equipment directions. Keep brass/zinc/iron/galvanized fittings removed and the aquarium absent throughout curing; never enclose fresh sealant. Reserve seven days after the final bead, longer where required. Cut open a matching-depth sample and reject uncured material or peeling from the coated offcut; odor loss alone does not prove cure. Repair failures and restart the hold. Only after the complete accepted cure, refit the finished cabinet door/hinge/strip units, catches and knobs in their labeled holes and repeat full swing, closing, screw-depth and strip-removal checks. Then proceed to steel-track bonding.

Check before continuing: The complete cure hold, cut-open depth sample and coating-bond trial pass; repair and restart the hold after any failure.

Required wait: Seven-day project hold after the final bead, extended as required; cut-open sample and bond acceptance before hardware refitting or steel-track bonding.

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58. Bond the steel tracks to their bare seats

Parts: KV993 / KV999 tracks and jambs; accepted PL Premium bond

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use Loctite PL Premium 1390595 only after the approved steel-to-bare-wood sample. Remove footprint masks; clean the wood and degrease received zinc-steel contact faces using the accepted preparation. Keep both surfaces dry and the rolling channels protected.
2. Bond each track or jamb only to its own wood member, never across a removable joint. Reference cured bed is 1/32 in (0.79 mm). Assemble within 15 minutes and brace straight for at least 24 hours, keeping adhesive out of glass and ball channels.
3. Reserve 48 hours at 78°F (26°C) and 50% relative humidity before loading; cold or dry conditions require longer according to the label and technical sheet. Check cured adhesion, straightness and the fitting gauge before cushions or final glass measurement. A failed sample or loose track requires an accepted repair and repeat cure.

Check before continuing: All four bonds have completed their required cure and the matched gauge moves freely.

Required wait: At least 24-hour bracing; 48-hour reference load wait under specified conditions, longer when required.

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59. Bond the four accepted jamb cushions

Parts: STOPLF/STOPLB/STOPRF/STOPRB and accepted contact bond

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use DAP Weldwood Original 00271 only after KV/DAP approval of the received zinc-plated steel and plain neoprene. Trial cleaning and two-face coating on matching offcuts. Never use this bond on EPDM, glass or HDPE.
2. Cut four 17 39/64 in (447.28 mm) × 0.28 in (7.11 mm) × 1/16 in (1.59 mm) strips. They fit between the horizontal tracks, with no tabs across the rails. Mask adjacent channels and apply the accepted thin contact-bond film by its label.
3. Fit each strip on its named jamb lane, press as specified and leave it undisturbed. The model film is 0.003 in (0.08 mm); measure the actual cured stack before glass sizing. Reject lifting edges or movement during repeated sample closing/service trials.

Check before continuing: Four cushions are secure, correctly placed and clear of track/guide paths.

Required wait: Seven days to the published maximum-strength reference; follow actual label and supplier requirements.

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60. Measure and release the accepted glass order

Parts: Accepted tracks, cushions, fitting gauge and both recorded final glass/shoe/carrier orders

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Reference glass dimensions are not a blind ordering instruction.

1. Confirm the preceding steel-track and cushion bonds have completed every required cure and sample check. Record actual outside track faces and the fully seated carrier/shoe geometry with the disposable gauge. Do not apply a second adhesive layer or assume its thickness from the reference model.
2. Reference panes are 44.1689 in (1121.89 mm) × 17 63/64 in (456.8 mm) × 0.2362 in (6 mm), approximately 16.95 lb (7.69 kg) each. These are NOT order sizes. Obtain matched-system acceptance and a fabricator’s field size; specify monolithic tempered, polished edges and no holes. Never cut, drill or grind tempered glass.
3. Have the fabricator and accepted-system supplier confirm pane dimensions, edge finish, mass, shoe seating, lower capture, overlap and supported removal. Record final shoe and carrier cuts; carrier reference length is 65.7533 in (1670.13 mm). Order only after H01 written acceptance and the received gauge trial.
4. Record the final sizes and clearances in the worksheet. Historical 144 in (3657.6 mm) opening and 2:1 proportion guidance does not resolve the current page’s 36 in (914.4 mm) pane description; this wider pane remains on hold until accepted in writing. Keep indoor zinc steel free of mist, condensation and bed material. No opening limit establishes a structural load rating.

Check before continuing: Bonding is fully cured, tracks remain straight, and the final glass, shoe and carrier dimensions have been recorded from the received system.

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61. Lay underlay and uncut folds on the land deck

Parts: DECK, UNDERLAY, LINER, CF2, CFR, CM2, CM3, CRU; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With roof and doors off, cut one 76 in (1930.4 mm) × 44 in (1117.6 mm) underlay blank and one matching 45 mil ethylene propylene diene monomer (EPDM) blank. Lay both on the deck with slack into corners. The membrane remains a single uncut sheet: the model shows its folded finished envelope, not notches to cut in the blank.
2. Fold uncut corners and pleats around all five intruding posts: CF2, CFR, CM2, CM3 and CRU. Keep slack over softened edges and trial the actual compressed underlay/fold bulk. No slit, splice or hole is allowed below the dry upper clamping band, whose bottom is Z = 20 1/4 in (514.35 mm). Only the scheduled clamp screws pierce that upper band; they do not pass through the basin below it.

Check before continuing: The sheet and underlay lie slack and protected around all five posts; there are no cuts, punctures or stretched corners.

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62. Fit twelve removable liner clamps

Parts: LINER, LCL, LCR, LCF1, LCF2, LCB1, LCB2, LCB3, LCQ2, LCQR, LCP2, LCP3, LCPR; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit the twelve rounded clamps only in the dry upper band, Z = 20 1/4 in (514.35 mm) to 20 3/4 in (527.05 mm); screw centers are Z = 20 1/2 in (520.7 mm), 5/8 in (15.88 mm) above maximum bed. Trial the actual uncut folds. Fit the five short post clamps first, then the five front/back clamps, and the two long sides last; remove in reverse. Use the revised LCL station clear of CM2.
2. Transfer the scheduled screw centers to the wood. Remove the loose liner and underlay before drilling separate clamp clearances and stopped receiver pilots. Refit the relaxed layers, then hand-puncture only the marked shank locations in the dry band. Never drill loose rubber around a rotating bit. Install the listed screws without crushing the sheet. Leave the basin below the dry band, corners and post pleats uncut and unpunctured.

Check before continuing: Only scheduled shank holes pierce the dry upper band; no slit or hole lies below it, and every short-post drive remains accessible in the stated order.

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63. Complete the shallow land-liner leak check

Parts: LINER, LCL, LCR, LCF1, LCF2, LCB1, LCB2, LCB3, LCQ2, LCQR, LCP2, LCP3, LCPR; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. After curing, test the land liner with 1 in (25.4 mm) of water for 24 hours. Inspect beneath the deck and outside, siphon all test water out and dry it. Repair and repeat if any dampness appears. This is a leak check, not structural proof. Never fill the coated tank bay with water; the separate aquarium contains the water. Refit the collars only after the tank is installed.

Check before continuing: No dampness appears beneath the land deck during the full 24-hour shallow check; all test water is removed and the area is dry.

Required wait: After all cure holds, one inch of water for a full 24 hours, then siphon out and dry.

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64. Glaze shoes and place both ball carriers

Parts: GL — Tempered glass leaf; GR — Tempered glass leaf; HL — KV995 glass shoe; HR — KV995 glass shoe; CARRIERL — KV997 free rolling ball carrier; CARRIERR — KV997 free rolling ball carrier

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Inspect the tempered panes and deburred shoes on a padded clean bench. Fit each 995 shoe to its matching pane using the actual Roll-Ezy fit verified in the make the track and liner fitting gauges operation; do not hammer a tight shoe onto glass. This family uses continuous free-rolling carriers, not individual wheels, aluminum-system vinyl, end caps or top clips.
2. Place one correctly cut 997 carrier on each 999 lower-track anvil. With the left leaf closed, its rear-lane carrier starts at the left stop; with the right leaf closed, its front-lane carrier ends at the right stop. Their about 65 3/4 in (1670.05 mm) reference lengths extend beyond the shoes so each shoe remains supported as its carrier travels at half door speed.

Check before continuing: Glass edges are intact, shoes fit without force and both accepted carriers sit correctly before the panes are installed.

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65. Seat the rear leaf before the front leaf

Parts: GL — Tempered glass leaf; GR — Tempered glass leaf; HL — KV995 glass shoe; HR — KV995 glass shoe; CARRIERL — KV997 free rolling ball carrier; CARRIERR — KV997 free rolling ball carrier

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With a helper, lift the left closing pane into the rear upper channel, bring its shoe over the carrier and lower gently. Fit the right closing pane in the front lane. Keep glass supported near both ends and prevent it twisting. Confirm that the curved shoes sit on the balls and the carriers remain inside their channels.
2. Slide each leaf through its full path and close onto the cushions with 1 in (25.4 mm) overlap. Check at both ends and the middle: smooth motion, no metal scraping, no carrier running out from under a shoe, and continuous upper-channel engagement. Reset any carrier that has crept before continuing; never force a jammed door.

Check before continuing: Both doors roll on the matched carriers, remain supported through full travel and have intact glass edges.

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66. Install anti-lift inserts around the parked panes

Parts: ALF1/ALF2/ALF3/ALF4 and ALB1/ALB2/ALB3/ALB4; sixteen #4 × 3/4-inch screws

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Remove the lock and have a helper control the seated pane. Each lane contains four strips. To expose a screw left of the enclosure center, park both panes fully right; to expose a screw right of center, park both panes fully left. Keep each loose strip supported while exposing its own two screws.
2. With both end strips absent and both panes parked right, insert middle strip 3 into the exposed left end and slide it to its mark. Then repeat the same insertion for middle strip 2. The strips pass above the glass without pressure. Hold it up without forcing the glass. Fit both screws of each middle strip from a clear pane position, moving the supported pane only with the driver removed and the strip controlled. Then fit the two end strips with the pane parked clear of each.
3. For service, remove both end strips first, parking both panes away from each exposed end; support and lower each end strip 2 in (50.8 mm), shift it 1 in (25.4 mm) inward from the jamb, then withdraw toward the room. Release middle strip 2 while supporting it, park both panes right, slide the strip left into the empty end and lower it 2 in (50.8 mm). Move it 1 in (25.4 mm) inward away from the jamb, then withdraw it toward the room. Release strip 3 and slide it through the vacated middle space to the left end; repeat the same lowering, inward shift and withdrawal. Remove right end strips with both panes parked left and shift those strips inward to the left. Repeat for the other lane. Install in reverse. Never lift a pane until all four strips in its lane are removed. Actual tool, grip and received-profile trials remain required.

Check before continuing: Both lanes have continuous capture; all sixteen screws and all eight strips can be safely installed and removed.

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67. Prove cushion and anti-lift retention

Parts: ALF1, ALF2, ALF3, ALF4, ALB1, ALB2, ALB3, ALB4, STOPLF, STOPLB, STOPRF, STOPRB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Inspect four fully cured bond-retained cushions between the horizontal tracks. No tab or screw enters a moving lane. Test repeated soft closure; peeling, shifting or contact with bare metal requires repair, full cure and a repeated trial.
2. At both ends and the middle, gently lift each pane. Its shoe must remain positively captured within the lower track. Unscrew the inserts and demonstrate lift-out with a helper, then reinstall and repeat the retention check. Correct any fit that allows derailment with the inserts installed.

Check before continuing: Neither pane can be lifted off its rail in any operating position; both remain removable after the inserts are unscrewed.

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68. Fit and test the ratchet lock

Parts: LOCK — removable housing; LOCKBAR — rear-leaf ratchet bar and clip

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Close both doors on their cushioned jamb stops. Fit the 963L ratchet bar to the rear leaf and its anti-spread housing across the overlap following the supplied orientation. Protect the polished edge; no improvised metal packing may touch glass.
2. Adjust the ratchet to secure both leaves without forcing or bowing them. With the key removed, gently test each door separately for sliding, spreading and lifting. The anti-lift inserts remain installed independently of the lock.

Check before continuing: The lock restrains both closed leaves without bowing them and releases predictably; anti-lift inserts remain independently secured.

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69. Fit pulls and measure upper service access

Parts: PULLL/PULLR — glass pulls; GL/GR — upper leaves; removable LOCK body

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Locate each pull with its nearest edge at least 3/4 in (19.05 mm) inward from that pane’s closing edge, clear of the jamb noses. Follow the pull maker’s cleaning, adhesive and dwell instructions. Prove the complete bypass path before bonding.
2. Remove the lock body before sliding. The reference single-leaf opening is about 42 1/2 in (1079.5 mm) × 17 5/8 in (447.68 mm). With both panes removed, the clear opening between jamb-channel noses is about 86 5/16 in (2192.34 mm) × 17 5/8 in (447.68 mm). The rear-leaf ratchet clip meets the opposite cushion before metal reaches the jamb; prove this with the actual lock. Reserve at least 41 in (1041.4 mm) width for equipment access; larger objects require both panes or roof removal.

Check before continuing: The lock holds both closed leaves and releases predictably; pulls do not collide and service access is documented.

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70. Secure the removable roof

Parts: P02 — Removable roof

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check that mesh, liner clamps and track hardware are complete before setting the roof down. Seat it without trapping the liner, glass guides or future cables.
2. Use the transferred roof stations: three screws along each side wood support, eight across the front header and eight across the rear upper wood support. Drill clearance through P02 and stopped pilots into the receivers.
3. Fit #8 × 1 1/4 in (31.75 mm) screws, tightening evenly by hand. Do not glue the roof and do not use the mesh as a handle. Check the doors again with the roof secured.
4. Keep roof screw locations accessible. Disconnect and remove equipment before roof service. Fixtures may sit above screen or mount inside only where their instructions permit, with qualified framing or another support carrying their weight. Mesh alone has no fixture load rating.

Check before continuing: The roof cannot shift or lift unintentionally, and both doors still operate without binding.

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71. Inspect the completed empty construction

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Inspect every current screw, all nineteen recessed retainer connections, all captures, glazing, roof, lock and anti-lift strips. Repair splits, burrs, loose fittings, exposed wire, stripped wood or coating damage before proceeding. Digital checks do not certify physical strength or containment.
2. Measure the closed gaps at the jambs, between the glass leaves, below the shoes, around the roof and at the mesh. Record actual values; the construction clearances alone do not establish containment for an animal or feeder.
3. Rehearse all service routes using the separate operations below: supported glass/insert removal, empty liner removal, supported cabinet door/strip removal and empty aquarium transfer. Remove the front collar with FAS and LEDF together; do not attempt to drive its blocked top screws while installed.
4. Check that the independent aquarium receiving, base-support, load and handling records are complete. Remove only COLL, COLR and COLB separately; COLF stays on the FAS/LEDF unit. Trial the unit’s finished end clearances and the four KR screw-access bores. Document a clear transfer route to an independently rated adjacent surface. No loaded aquarium is moved.

Check before continuing: The completed construction record has no unresolved defect. Animal and equipment commissioning remains a separate step.

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72. Remove and refit glass for service

Parts: Both glazed leaves, lock and removable inserts

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Empty the enclosure and disconnect/remove equipment. With a helper supporting the glass, remove the lock body and both lanes of anti-lift inserts. Support the front leaf first, then the rear; never use the edge as a lifting handle.
2. Move the front leaf 2 in (50.8 mm) away from its closing jamb. The reference path lifts 3/8 in (9.53 mm), tilts the bottom 3 degrees toward the room (about 0.941 in (23.9 mm) at the bottom), lowers 1 in (25.4 mm), then withdraws 6 in (152.4 mm) toward padded supports. Keep the pane fully supported throughout. Actual accepted profile clearance controls; never force glass. Repeat for the rear leaf after the front one is safely removed.
3. Vacuum and wipe tracks without flooding; dry them immediately. Refit rear pane first, then front. Reinstall all inserts and lock and repeat full travel, closed-gap and anti-lift tests before returning an occupant.

Check before continuing: The complete empty service route is clear and retention passes after reassembly.

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73. Remove the cabinet door and strip as a unit

Parts: CAP1/CAP2, CHB1/CHB2 and their attached hinges

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Open the cabinet door and support its entire weight. Remove the three mounting-strip screws, keeping the door, continuous hinge and strip together; do not pull on the knob.
2. Lift the supported unit forward to expose the covered retainer drives. Keep all labeled fasteners. Refit with its original strip screws, restore the full veneer gaps and check at least 90-degree swing and catch operation.
3. Inspect equipment and hose removal through the actual finished opening; never use a cabinet door as a carrying handle or animal lock.

Check before continuing: No hidden drive remains inaccessible; doors refit without rubbing.

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74. Empty and remove the land liner

Parts: Twelve LC clamps, empty one-piece EPDM and protective underlay

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Remove animals and equipment and scoop the full bed into containers. Remove upper panes or roof as needed; never pull a liner loaded with bed or water.
2. Take the long side clamps off first, then the short post and straight clamps. Label all twelve strips and screws. Lift the empty uncut sheet and underlay without tearing a folded corner.
3. Inspect deck, eased post edges, recess padding and cabinet underside. Repair the cause of abrasion or dampness; finish all repair cure waits. Refit short post clamps before long side strips, then repeat the 24-hour shallow leak check before refilling.

Check before continuing: No damage remains; repaired material and a repeated shallow check are accepted.

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75. Transfer the empty aquarium onto qualified support

Parts: TANK, P01, KR, FAS, LEDF, COLF, COLL, COLR, COLB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On qualified full-footprint support, remove side/rear collars and then the FAS/LEDF/COLF unit and KR. Clean the aquarium-bearing floor. Confirm the maker’s complete-base support and level the furniture, never one tank corner.
2. With qualified handling help, lift and transfer the empty received aquarium into its measured position. Confirm complete base bearing and clearances. Refit KR, the supported FAS/LEDF/COLF unit and side/rear collars. Wood supports carry the collars; no load bears on the aquarium rim or glass.

Check before continuing: The actual aquarium is level on its complete supported frame, all four collars are secured clear of it, and the empty-tank removal procedure is practical.

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76. Fit equipment and route hoses through existing openings

Parts: TANK — Seapora 59211 nominal 50-gallon framed aquarium; DIV — Tank-bay divider; COLB — Removable rim collar; CAP1 — Cabinet 1 hinged equipment-access door; CAP2 — Cabinet 2 hinged equipment-access door

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Select filtration and hoses for the actual aquarium and occupants. Finished cabinet openings are reference 20.939 in (531.85 mm) × 10.439 in (265.15 mm); clearance below the front ledger is 12 19/32 in (319.88 mm). Check the whole equipment envelope, hose bends, ventilation, lid removal and extraction before purchase. A canister filter is not assumed to fit. Use existing divider and rear-collar openings without kinks, abrasion or liner penetration.

Check before continuing: Equipment, hoses and lids fit and can be removed; routes are smooth and unpinched with no liner penetration.

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77. Leak-test the aquarium by its maker’s instructions

Parts: TANK — Seapora 59211 nominal 50-gallon framed aquarium; P01 — Floor

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Leak-test the aquarium according to its own instructions before habitat use. Fill incrementally on its final qualified support and inspect for leaks, loss of level or movement; drain immediately if a fault appears. Select operating water depth for the actual animal. The 50-gallon nominal product volume is not a prescribed fill level.

Check before continuing: The maker-directed aquarium test passes on final qualified support with no leaks, movement or loss of level.

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78. Limit the land bed and qualify water access

Parts: TANK — Seapora 59211 nominal 50-gallon framed aquarium; LINER — Continuous folded EPDM basin; SUBSTRATE — 4.25-inch total bed

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Limit the entire land drainage/substrate stack to 4 1/4 in (107.95 mm), measured from the finished liner bottom at 15 5/8 in (396.88 mm). The reference top is 19 7/8 in (504.83 mm), above the nominal tank rim: do not assume a flush transition. Provide stable nonabrasive entry and exit routes suited to the eventual species and every intended water level, supported from qualified structure without loading the tank rim or puncturing the liner. The conservative clear land rectangle above the maximum bed is about 51 3/8 in (1304.93 mm) × 17 15/16 in (455.61 mm) × about 25 15/16 in (658.81 mm) below the roof ribs; actual folds, ramps and equipment reduce it further.

Check before continuing: The complete bed stays within its maximum depth; independent stable entry/exit routes suit the actual occupant and operating water level.

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79. Rehearse the complete empty aquarium removal

Parts: TANK, KR, FAS, LEDF, COLF, COLL, COLR, COLB; named parts and exact stations in workshop reference

Tools / setup: Measuring tape, square, pencil and the tools named below

1. For removal, follow the illustrated service sequence: drain completely and empty all contents; remove side/rear collars; remove FAS with LEDF and attached COLF; remove KR; lift and transfer the empty tank to an independent rated adjacent level support. Never drag it or move it loaded.

Check before continuing: With the aquarium empty, each removable unit and kick rail clears; the qualified supported transfer is practical and refitting restores all clearances.

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80. Qualify the actual occupant and equipment

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Select the intended species, life stage and number of occupants against current care requirements using the finished usable interior, not the nominal 96 in (2438.4 mm) × 24 in (609.6 mm) × 48 in (1219.2 mm) shell. This generic guide assigns no species suitability.
2. Qualify every gap and the mesh opening for the occupant and feeders. Add a mechanically retained finer barrier when needed, then reassess ventilation, visibility, cleaning and equipment performance.
3. Choose heat, light, ultraviolet, water heating and filtration for the actual animal. Use guarded equipment as its instructions require. A fixture may mount inside or above the mesh only with the specified combustible clearances and qualified support carrying its weight. Keep hot parts away from wood, liner, sealant, glass and animal contact; do not rely on the mesh to support equipment.

Check before continuing: The actual occupant, usable space, containment gaps and equipment have a documented acceptance plan before commissioning.

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81. Commission the habitat before animal entry

Parts: Named parts in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Route protected cables and hoses without piercing the land liner. Make drip loops below every plug and use a ground-fault circuit interrupter (GFCI) protected supply. Control heat with a compatible thermostat as the equipment requires. Keep mains connections outside wet and splash zones, and disconnect power before water or equipment service; this guide contains no building-wiring instructions.
2. Commission the complete habitat without animals. Measure water and basking temperatures, humidity, filtration flow and water quality against the eventual species requirements until they remain stable over day/night operation. Biological filtration must be established and verified by water testing where required; a fixed week is not proof of cycling. Verify usable exits at every operating water level. Keep condensation and mist off the indoor zinc tracks, correcting the arrangement if they remain wet. Record passing results before animal entry.

Check before continuing: Recorded day/night conditions, water quality, filtration, exits and containment meet the selected occupant requirements before animal entry.

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