I wanted to share my experience building the WF Version 2.0 Standing AirLift Mini (SAM) in hopes that someone will find it helpful when setting up their own system. I encountered some problems and posts by people who had gone before me were tremendously helpful; I couldn’t have done it without the community.
I have been building hydroponics systems off and on for a few years now. I have experimented with NFT and ebb & flow systems primarily. The windowfarm system interested me because of its ease, simplicity, aesthetics of the designs as well as the ethos, philosophy and community-supported approach that form the foundation of the project.
I decided to go with the SAM as it presents an inexpensive, both in terms of time and money, entry into windowfarming. I have a high-need baby who drains both resources at the present moment so it fits my particular situation well.
Materials
- (1) Two-Nozzle Aqua Culture (Walmart) Air Pump
- (1) 10′ 3/8 ” Exterior – 1/4″ Interior Tubing
- (1) 8′ Aquarium Airline Tubing
- (2) Check Valves
- (2) Air Needles
- (1) 2.5 Gallon Water Jug
- (1) 5′ Tomato Plant Stake
- (1) Package of 4″ Zip Ties
- (1) Package of 14″ Zip Ties
- (2) Aquarium Airline T-Joints
Process
1. Bottles: Having attempted to cut plastic bottles in the past, I dreaded this part of the process. Water bottles are generally thin and crease easily. In my experience, they confound attempts to cut them but directing the scissors or knife in obscure and unwanted directions. So I did a little research on the site and discovered a genius suggestion: fill the bottles with water and freeze.
I filled the bottles with water, leaving a couple inches of air at the top. I also left the caps off. This kept the bottles from exploding in the freezer. It took almost 24 hours to freeze completely through. I used the template and a wet-erase marker to trace the lines. A utility knife sliced easily through the plastic and the top bit of ice, staying on track for the most part. The ice also held the cut piece in place, preventing it from twisting around and getting in the way. I let the ice melt and was left with bottles cut much cleaner than I had hoped for.
The connected bottles served as a height reference for the rest of the project to make sure the nutrient solution reached high enough.
2. Air Lift: I temporarily connected the airlift tubing to the column support (the tomato stake) using string to tie it in place for testing.
3. Air / Nutrient Solution Injection: I cut the bottom of airlift tubing at an angle. I then attached two lines of mini-airline tubing (that’s all I had at the time) to the two injection needles. They were small enough to slip inside the ends of the needles. I used aquarium sealant to secure and seal the tubing to the needles. I had to buy normal aquarium tubing at this point. I used used a connector to connect the mini-airline tubing from the needles to a standard-sized aquarium tubing. This tubing connected to the air pump, one line per nozzle, with a check valve on each line. I inserted the needles on opposites of the airlift tube four inches from the bottom.
4. Testing: I filled a five gallon bucket to the same height as my reservoir, placed my plumbing into the bucket and plugged in the air pump.
Problem: The nutrient solution only bubbled up about a foot and a half. I held the stake perfectly vertical and made sure the airlift line was attached straight. No luck.
Attempted Solution #1: I thought the air pressure might be too low since I was using a Walmart air pump. I removed the check valves. It pumped higher, but only by a few inches.
Attempted Solution #2: I then thought that maybe the pressure was too high. Unlikely since I was using a Walmart pump, but I decided to try it anyway. I connected both air lines to a single airline and check valve using a t-joint. Now only one nozzle of the air pump was delivering air to the injection needles. Again, I only gained a few inches. I removed the check valve, which only gave me an extra inch or so.
Attempted Solution #3: I read about a modified version of the intake assembly on the instructions page for the SAM windowfarm. It reverses the intake process by delivering nutrient solution through the needles and the air through the bottom of the airlift tubing. To accomplish this, I cut the tubing connected to the needles a couple inches below the needles and then sealed a single airline tube to the bottom of the airlift tubing using aquarium sealant.
After waiting another 48 hours for the sealant to cure, I tested the system. This new configuration pumped a little higher, somewhere close to three feet but still not high enough. Some air leaked out of the needle tubing. When I removed a couple inches of water to simulate evaporation, the system failed miserably. This is unacceptable as I need a system with a certain level of tolerance.
Attempted Solution #4: At this point, I feared that my air pump was just too weak and reluctantly started to price pumps. I also did a lot of research on the site and discovered the alternative T-Joint Airlift method. I decided to try this configuration. I connected my air pump tubing to the left side of the t-joint with a three foot coiled length of airline tubing connected to the right side. The top part of the t-joint connected to the airlift tubing. I used another t-joint to connect both of my air pump nozzles to the air pump tubing and employed a single check valve to get the most pressure out of the pump as possible.
Unfortunately this method delivered similar results to my previous attempted solution. It also leaked a great deal of air from the intake tubing. I read that it is normal to have some air leak initially but that it should stop after a few seconds. That was not the case with my system. I tinkered with the configuration, removing the check valve, trying to use one nozzle instead of two and increasing the length of the intake coil to four feet. Nothing worked.
Frustration: I enjoy the process of engineering and building hydroponics systems. I am used to systems not working. But I’m also used to finding solutions. I had tried everything I could think of short of buying a new pump. While in the process of seeing if I could afford a pump this month, I thought of something I hadn’t tried.
Solution: I replaced the 3/8″ ext – 1/4″ int airlift tubing with the standard-sized aquarium tubing used in the rest of the system. I connected both nozzles to a single line of tubing using a t-joint and added a check valve to the line. Finally, I connected the tubes to the appropriate ends of the t-joint. I didn’t want to get my hopes up so I drained the water to a real-world level (simulating days of evaporation) before plugging in the air pump. The nutrient solution intake coil leaked lots of air and my hopes fell. Then it stopped leaking, just like the said should happen.
Then it just worked. The pump produced a modest flow rate of one drip per second (200ml per hour), but it worked.
I tried attaching the air line tubing to just one nozzle of the pump. This time no air leaked on startup but I still received the same flow rate. I added an air stone using the free nozzle to oxygenate the nutrient solution.
5. Construction: With the plumbing working, I was ready to connect everything. I propped the 2.5 gallon water jug on its end, which gives me access to pour in solution through the sprout. I drilled holes in top for the air and airlift tubes. I weighted the intake coil, air stone and t-joints using rocks and 4″ zip ties and arranged them on the bottom of the reservoir. I attached the column support to the handle of the jug and the airlift tube to the support using 4″ zip ties; I made sure not to squeeze the airlift tubing too much with the zip ties.
I wrapped the bottom of the bottles with a layer of black electrical tape and then covered it with a layer of white electrical tape. I then attached them to the support using the 14″ zip ties. I also inserted a few inches of aquarium tubing into the bottle caps, sealed with aquarium sealant and then screwed them to the bottles. This will allow me to direct the nutrient flow for each bottle.
When I tested the system with the reservoir fully filled (a good two inches higher than I had been testing with previously), the system delivered a much higher flow rate. I still need to test it to find out exactly what that flow rate is.
I seated in the net pots in the bottle and had a completed windowfarm on my hands!
Epilogue
This may be a long post, but I didn’t really write it for casual blog readers. Instead, I hope that its length and detail will help someone in the future who finds the post while searching for solutions to problems they are experiencing. If you read it just for the heck of it, then allow me to make the observation that you are a rather rare and patient breed for the internet.
Photos
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The air pump that powers the system. One line lifts the nutrient solution to the top of the column while the other oxygenates the nutrient solution.
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The various tubes running in and out of the reservoir.
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The top bottle with the air lift line delivering the nutrient solution to the column.
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Another view of the top bottle.
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The connection between the column support and the reservoir.
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The completed windowfarm.
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The air pump, reservoir, column support and return tubing.