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How To build a
Water wall

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How to build a water wall

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TOOLS MATERIALs
Table Saw - 4x8 sheets of plywood Sandeply
Miter Saw Glue both wood glue (tightbond 3) and an industrial
Circular Trim Saw level contact cement (usually red) used for formica and
Impact Driver similar applications.
Drill Driver 4x8 1/16th thick metal laminate.
Countersink Bits 1.5 wide 1/16 thick aluminum strips (8 in length).
J Roller Wood dowels
Router Screws
Flush Trim Router Bit PVC: tubing, elbows, Ts,
Fluted Trim Bit Reinforced plastic hose 1 in diameter
Metal File Pump
Hole Saw 1 pipe clamps
Forstner Bit Expandable and retractable pipe clamps
Pipe Wrenches LEDs waterproof light fixtures
Clamps PVC pond liner
Level PVC shut-off valve
Rafter Square 200 lbs. of black river rock
Framing Square Bath tub drain set-up
Tape Measure PVC cement
Safety Goggles
Face Mask (for full face protection when cutting metal
sheeting)
Files
Paint Roller/Roller Cover/Paint Pan

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CRAFTSMAN PROJECT PLANS
How to build a water wall
SKELETON
Building Your Boxes and Wall

Follow the diagram attached to the project plan file for

your measurements a few steps have been changed
which will be outlined here.
The length of the boxes will be in direct line with the
length or width of your wall that you build - once you
decide on that - you will have the box length.
Now its time to build your wall. You have your width -
now decide your height. The wall serves both as structual
support for the boxes as well as housing the pump and
plumbing for the water flow. The walls depth should be
at least an inch deeper than the depth of the pump you
are using.

Cut your plywood for the bottom as well as the top

boxes.

Build your boxes using wood glue and screws make sure
you counter sink the screws so that no screw heads are
above the surface of the plywood.

TOP BOX BOTTOM BOX

WALL PANEL 1

WALL PANEL 2
SUPPORTS

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How to build a water wall
Skinning & Sheeting
Once the boxes and wall are both assembled (3 separate
pieces) measure and cut your metal sheeting. We used an
aluminum-type sheeting that has vertical wave patterns.
The sheet stands 8 high.
Use the trim saw to cut your metal sheeting make sure
that you are making all your cuts so that the materials
wave pattern is ALWAYS vertical.
Youll be cutting material for EVERY exposed plywood
edge: fronts, tops, sides, interior edges EXCEPT for
any plywood areas that will not be exposed once the 3
pieces are all joined together. For example: the backs of
both boxes where they will attach to the wall.
RESERVOIR
Next up is the secondary interior reservoir box. This will
catch the water as it comes down and funnel into the
pump to keep your water wall in action.
This bottom box is angled down to meet in the center for
proper draining. Youll need to install two boards that sit
flush on the floor at the bottom of the box. Cut the tops
of each board to match the angle at the bottom. This
supports the boards and ensures that everything looks
nice and flush.
Decide where your drain will be and mark the center. We
went 3 from the back of the box.
Mark the same area on the exterior back of the 1st bottom
box you remember that one from back in the Skeleton the inside ONLY use screws on the BACK surface of the
section. Place the larger exterior box over the smaller
interior box. Use a forstner bit to cut out your drain holes
RESERVOIR
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Once your pieces are cut apply two coats of industrial
contact cement (usually red) to every area that will be
sheeted. Wait 15 minutes or until cement is tacky.
Apply a coat of contact cement to the back side of every
piece of laminate.
After metal is attached use the router with a flush trim bit
to take off all overhanging edges. Use a fluted trim bit on
areas that metal meets metal to avoid scratching up the
area that is not being cut. Use a file to take off any burrs
or rough edges of the metal sheeting.
If you would rather have a natural wood style, you can waterprrof
and finish your wood boxes rather than apply a veneer.
in both boxes at the same time. ensuring that they are
exactly the same at exactly the same placement.
Remove the larger exterior box from the smaller interior
box. Cover the inside of the smaller box with 2 coats of
contact cement, let sit for 15 minutes or until tacky.
Once ready for application take your PVC pond liner and
attach it to the interior of that smaller box. Try to pull it as
tight as possible (without tearing it) while at the same time
pressing it to the cemented interior of the box, ensuring the
interior is watertight.
Once the contact cement has dried cut your drain hole and
put the larger exterior box back on top of it. Use glue on
external box. This bottom box will now be 1.5 thick up
from the original .
DRAIN HOLE
PG. 3
CRAFTSMAN PROJECT PLANS
How to build a water wall
TUB DRAIN
Install the tub drain using the washer that comes with for the hose that comes from the pump and leads into the
it to ensure water tightness. Silicone the area where the PVC set up in the top box.
drain meets the PVC pond liner.
Drill a 1 wide hole in the same lower area in the back
Take the top box and drill a 1 wide hole in the center wall using your forstener bit. This is for the hose that will
near the top of the back using a forstner bit. This will be lead from the tub drain to the pump.

PLUMBING
PVC TUBING / ELBOW / TS

3/4 PVC

HOLES 1/4 APART

VALVE FLEXIBLE HOSE

TUB DRAIN

WATER PUMP PVC TUBE

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How to build a water wall
lighting
When thinking about using lighting for any project
involving water - remember that you need to use a light
or lighting system that has a waterproof housing.
We went with a steel encased LED lighting system because
of the durability, longevity and brightness of the LED bulb.
To get the most light from the source we will create a lid
for the top box. First rip or cut some cleats to install on
the interior of the top box. Install them 3/4 of in from
the top so that your lid sits flush with the top of the box.
assembly
Putting it all together.
Once every part is assembled youre ready to make
these pieces one working unit.
Lay your boxes on the floor front side down (make
sure that the top box and bottom box are in the right
position)
Then move the wall you built on top of the boxes -
face down - line up the bottom of the wall with the
bottom of the bottom box.
Attach with screws.
Then line up the top of the wall to the top of the top
or upper box - attach with screws.
With a helper - carefully lift the entire piece so that it
stands upright.
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Then cut a piece of plywood that would fit exactly inside
the inner dimension of the top box. Attach your lights to
the underside of the lid - so that the light shines down
and directly in to the flow of the water.
You may decide to change the direction or angle of the
lights - so you can adjust the positioning of the lights to
suit your needs.
LED PLATE
LED LIGHT
Now move it into place as close to where your final
destination for your water wall will be.
Connect and attach all your plumbing - flexible line,
valve, hard PVC lines to the top PVC water inlet as
well as the bottom box drain - use PVC cemet where
applicable - use pipe clamps or straps where the
flexible hose meets the valve and pvc pipe.
Move your wall into place find studs and attach
using bolts for added security.
Fill the bottom reservoir box enough so that water
covers the drain opening completely.
When first turning on the pump - make sure to turn it
on and off 3 times quickly to prime it - then turn it on
and let the water flow.
PG. 5
CRAFTSMAN PROJECT PLANS
How to build a water wall

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