DWC frame

This is how I build the frame for the deep water culture (DWC) unit for my aquaponics system.

This is the initial plan for the DWC frame. Pond liner will be laid inside the frame to hold water for the hydroponic component of the system.
Measuring out the woods to be cut. The styrofoam board is 2 by 4 feet, and I add 1 inch to the frame width & length to give more room for adjustment and to prevent the board from fitting too tightly.
Planing the woods, this will give smoother surface for varnishing later. These wood dust would go to our composting box.
The standing part of the frame, 36 of them.
Left aside for the varnish to dry. I choose to varnish them to prevent it from rotting quickly due to rain and termite. I plan to reuse it when we moved to our own village house in the future.

One thing I learned when working with varnish is I need a lot of thinner to dilute the varnish. The way I do it is by pouring some varnish into paint tray, mixed with some thinner, and paint a thin layer on the wood. However thinner evaporate quickly and the varnish eventually become thicker again, so I have to regularly add thinner to the varnish.

These are for the 4-foot frame width part.
And these are the 12-foot frame length, already planed and going to be varnished next.
After planed, varnished, re-measured and re-cut, these woods are joined together using 1½ inch tapping screws. I drilled the holes for the screws first so that it can be fitted without breaking the wood.

Not an easy task to do, some of the wood are bending so need to use more force to screw at the right place. Some are hard wood, so when I drilled it continuously, the drill bit become too hot and break eventually. If I use small drill bit size, it’s harder to screw, and some screws couldn’t go in, I had to cut them and replace with nails.

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