I spent most of Friday thinking about the flow problem in the tank. Trying to approach it scientifically.
I looked up the specs again on the algae free kit - black prop (which I was using) and it is rated by the manufacturer @ 1400 gph on a maxi-jet 600. I looked up the sure-flow kits for the maxi-jet 600 and they were rated at 800~1000 gph. I took a close look at the enlarged pictures of the sure-flow kits and the prop assembly didn't look any different - in fact they say they use the magnet assembly from the maxi-jet maker in Italy....so I started thinking. Chances are they are both using the same magnet assembly and shafts (because they truly look exactly alike). The maxi-jet 600 pump is turning at a constant rate. So the only difference has to be in the shape and overall design of the propeller itself. I thought about purchasing replacement sure-flow 600 props and put them into the kit I already have - would help off-set the costs so far. But, I've modified impellers before to adjust flow rates with HOB filters and such, so why couldn't I modify a propeller to reduce the flow on these mod kits. I really like the circulation and pattern that the propeller based pump gives, it's just too much for my tank - in my opinion.
I have the 2100 props from the kit and I'm not imaging that I will be upgrading to maxi-jet 1200's anytime in the near future, so I took a look at the possibility of modifying those(and that way still have my original 1600 props). The 2100's are made with a white, softer, plastic/vinyl material. That's good since it would be easy to trim with a standard x-acto knife,but may not end up being that durable in the long run - I'll take my chances without spending anymore money right now...
I made a paper pattern of the 1600 prop blade and used that as a starting point for modifying the 2100 props. I marked that on the prop and then trimmed it down with the x-acto knife. I then trimmed it down a bit more - to make a smaller prop with hopefully less water pushing power. I filled the bathtub with water and gave it a try. My first attempt was unbalanced and so the pump wobbled and made a lot of noise. Plus it didn't seem like the flow was any less than the standard 1600 prop (I put one in the other pump and put it along side the modified one for comparison). I decided against putting it in the tank that way and gave up on the idea.
Later that night, I couldn't sleep so I took another look at the modified prop and evened the sides out more. Then I went ahead and tried it out in the tank to see how it went. It didn't do too bad and there was no more noticeable hum than there was with the straight 1600 prop. the flow was reduced, but the was still plenty of circulation. I took and modifed the other 2100 prop like the first one and gave that one a try. It was a little more powerful than the first (even though it was the same distance underwater as the other, it would make a whirlpool from time to time) - cutting them by hand didn't make two exact copies (not that I was expecting to be that good at it), but overall it was a good start. I let it run that way overnight - both pumps running on the alternating cycle.
In the morning, things were still looking pretty good, but there was a little sand shifting at the front of the tank and the fish were still hiding in the corners. I decided to give the inhabitants a bit of a break that day and unplugged one of the pumps - the one that appeared to be most responsible for the shifting and just let the tank run with one pump for the day (cycled on and off with no flow during the time the second pump was supposed to be on). Everyone seemed to like that - the fish would hide a bit when the one pump was on and then come out when it was off. That night I trimmed the props a bit more trying to further reduce the flow and get the two pumps more equal. I also readjusted the direction so that the pumps were pointed toward the opposite corners so they would have the longest distance before hitting the tank walls. I let it run that way overnight.
The combination of the two seemed to correct the sand problem as there was no shifting in the morning, but still a good flow and I could see the sand on the sides looked a bit cleaner. It's run that way for the last day or so and still looks good. I guess there could be a little less flow for the fishes sake, but they were out a bit more last night when I got home. The torch corals seem to like the flow - they were about halfway extended when I got home (which is more like they were with the lower flow 606's). There might be an additional tweaking necessary to make everyone more happy, but I didn't want to cut it down so much that it wasn't enough. As I put coral over the top of the LR "reef", that might help reduce and further diffuse the flow so I may be at the "sweet spot" now. If the fish look like they are adjusting, I'll probably just leave it for now. Will definitely purchase a varible speed pump w/controller setup in the future - just can't afford it now...
As I get time, I will post closeup pics of the tank and the mods to the props. I've got a good growth of hair algae beginning on the upper areas of the tank and I can see some sort of whiteish bugs in the fuge, so it looks like things are starting to take off! I'll have to get a full CUC going in there around the end of the month (should be about right for enough growth for them all to live on). I only had the pistol, two large hermit crabs, two emerald crabs, 3 adult snails and a few baby snails left in the old tank that were brought over and I picked up a pepermint shrimp last weekend to help out. I'll have to run some new tests to see how the water is doing. Well that's all for now....