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Fabrication

Fyke trap

Catching a big fish requires a big trap. FISHBIO recently initiated a trapping and tagging study of striped bass on the San Joaquin River, and we’re using fyke traps to catch these large, anadromous predators. Fyke traps have been used around the globe for centuries to catch a variety of aquatic species. A fyke trap is essentially a pen or cage with a funnel-shaped opening that narrows toward the interior of the structure. Migrating fish follow the funnel and swim into the opening of the trap. Once inside, they have a difficult time finding the opening to escape because they tend to keep close to the outer walls of the trap.

We opted to use a trap design that the Department of Fish and Wildlife (formerly Department of Fish and Game) has used in the Sacramento River since the 1950s, first to estimate salmon and steelhead runs and later to estimate striped bass populations (Hallock et al. 1957). The fyke traps are large cylinders 10 ft. in diameter and 20 ft. long—and unfortunately, they are not readily available for purchase.

With a little research and a visit to see CDFW’s traps, our Fablab made quick work of building a couple of fykes. They started by rolling and welding steel pipes into 10 ft.-diameter circles for the frame and smaller circles for the interior cones. Then they welded the frame together, forming something resembling the nosecone of a rocket. Our technicians stitched together and cut plastic fencing to form the cone shape of the fykes. The design we used includes two fykes within the trap that feed one into the other. The inner funnel has a smaller opening that leads to the trap livewell, making it more difficult for the trapped bass to find an exit. We wrapped the entire cylindrical structure with chain-link fencing and added a couple of access doors to the sides of the trap. Once completed, these behemoth fyke traps were loaded onto trailers, transported to our sampling sites, and rolled into the deepest portion of the river channel. Watch for future posts on the success of our trapping effort!

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Fabrication

Sanding a tabletop

We have featured the artistic creations of our fisheries technicians before, such as a gate with a riverscape scene or iron yard art (Artistic Outlet), but our design capabilities don’t stop there. When it came to furnishing the inside of our offices, we wanted something more original than typical particleboard tables and desks. We opted for concrete because of the flexibility it offers. With each new piece of furniture our designs become more creative, from a salmon silhouette embedded in the center of a table, to polished stones forming a meandering stream across a countertop, to painted steel trout cutouts adorning the base of a desk. We find we are constantly surrounding ourselves with reminders of the habitat and wildlife that we so enjoy working with.

The process of making a concrete tabletop starts with building a form out of melamine panels and sealing the seams and corners with silicone caulking. Inside the form we construct a wire or rebar skeleton to give strength to the thin concrete slab. Anything that we want to embed in the tabletop, such as wood, stones, or precast designs, is placed in the bottom of the form facing downward. We use a high strength concrete mix, like Quikrete® 5000, and combine it with water and coloring until it achieves a stiff, moldable consistency. The mix is then poured into the form and thoroughly tamped or vibrated to remove air pockets. We level the surface using a straight board (screed) to scrape off any excess mix. As the concrete begins to set, the surface, which will become the underside of the tabletop, can be smoothed with a trowel. After a week of curing the concrete slab can be turned over and the form removed. To get a smooth finish on the tabletop, we wet sand it with increasingly finer grit sanding disks, and then apply a water sealer. With some imagination and ingenuity, the design possibilities are limitless.

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Fabrication

trailer welding

Our multi-talented fisheries technicians lead a life of variety: when not surveying fish in the field or building equipment, they also serve as boat and vehicle mechanics. This includes regular maintenance and upkeep—or, in the case of the trailer shown above, retrofitting a piece of existing equipment to meet our needs. We had to make some modifications to a used trailer we bought for one of our boats to make it a better fit. This included lengthening the trailer tongue, mounting a new hitch, and repositioning the winch so its handle would not hit the boat when turned. A fresh coat of paint, new carpet on the bunks, and rewiring the lights will complete the trailer upgrade.

Although many of our technicians are handy with a wrench, one was an actual a mechanic before joining FISHBIO. He handles some of boat and truck maintenance when he has time, as shown below–everything from oil changes to replacing gaskets. We’re thankful our technicians have a diversity of skills to keep our shop and fabrication lab running smoothly.

boat maintenance

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Fabrication

Salmon gate

The technicians in our fabrication lab can build just about anything, and have a keen eye for nature to boot. Add a little artistic flair, and you can get some impressive results, like this salmon-themed gate one of our techs has been constructing. Here you can see the work-in-progress propped against an orange welding shield, which blocks dangerous light from people not wearing a welding mask. To create this work of art, Earl first drew the design on large paper to make templates of fish and rocks, which he traced onto 1/8-inch steel sheet metal. Then he rented a plasma cutter to cut out the metal shapes, welded 1-inch square tube steel to make the frame, and bent ½-inch rods to simulate water. He has a variety of looks to choose from for the finished product, such as natural rust, polished steel, or paint. If you stop by our Oakdale office, you can see some of Earl’s other handiwork on display in front of our shop—we gladly encourage his creative expression!

Plasma cutterYard art

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Fabrication, Monitoring, Telemetry

Last month we mentioned we were in the process of building a large, remote antenna array designed to detect and record passages of fishes and turtles tagged with Passive Integrated Transponder (PIT) tags. As our FABLAB crew can attest, many hours were spent constructing these supersized antennas.

With required dimensions in hand, we started by constructing the fiberglass shell. Since this array of three antennas will have to withstand high flows within the diversion tunnel, we used a curved mold to make the cross members of the antennas as hydrodynamic as possible. Once the rectangular shells of the antennas were produced, the electrical wiring was added. It only takes a couple wraps of a small gauge copper wire to produce the magnetic field required for charging the small PIT tag transmitters. After carefully positioning the antenna wire, we connected it to a tuner and tag reader from Oregon RFID, and then tested it for function and tag detection rate. With the electronics completed, more layers of fiberglass and Kevlar® (a high-strength, synthetic material) were applied and sanded until the desired shape and strength was achieved. Now that they are fully assembled and tuned, the three antennas can detect and record any tag passing through the center of the array. Watch for an update once this antenna is installed inside the subterranean tunnel and exposed to the full force of winter flows.

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Fabrication

You recognize their call, by the sound of metal grinding metal, the chirp of the forklift as it maneuvers heavy equipment into place, or the concentrated whoosh of the acetylene torch. Though they’re sometimes hard to spot, the elusive FABLAB technician Technica fabricatus is often found deep in the shop amongst the fiberglass and sawhorses, with its head buried in the latest project. If you can catch one of these fab-techs in between runs for additional supplies or reviewing project plans with technical design staff, it is a rare and short-lived treat before they’re back to the task at hand.

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Fabrication

We often need to fabricate specialized instruments for unique applications. In this case, we wanted underwater lights that operate on a timer to use with an existing Vaki Riverwatcher system owned by Seattle Public Utilities. We opted to use LEDs (light emitting diodes) because of their longevity and low power requirements. LEDs emit light without burning a filament, as in conventional lights, so they don’t burn out. The challenging part of the fabrication is sealing the ends of the light tube to ensure the light is waterproof. We tested these lights to be waterproof up to 10 feet deep, which should work well in the Landsburg Fish Ladder where the lights are going to be used. An advantage of custom making the underwater lights is that we can design them to operate on a conventional 120 volt AC power supply or on a 12 volt DC battery.

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Fabrication

We have made significant progress on the fabrication of our “Fish Racetrack” since we last posted on the project. Once the flume tank was framed and covered with wood sheeting, the surface was sanded for an even finish. In order to achieve a smooth, water-tight barrier the whole tank was covered with fiberglass. After some background research we decided to use a marine-grade epoxy by West System, because their waterproof formula is safe to apply and will not leach harmful contaminants into the water. A layer mesh fiberglass cloth was applied to the entire surface for strength, followed by multiple coats of epoxy resin. Sanding the entire surface between each layer of epoxy was one of the more time consuming tasks. The industry standard aqua-green color additive was mixed with the resin and applied to the interior of the tank, whereas we finished the outside with a little FISHBIO flare. Watch for our next post on this project, when we tackle the plumbing and filtration system.

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Fabrication, Research

We have been working with the U.S. Forest Service to test a new resistivity fish counter devise. In order to conduct laboratory trials we are constructing a flume, which is a fish tank resembling a racetrack. A flume is basically an artificial channel used to circulate water and simulate flowing water conditions.

This is the first in a series of blog posts documenting the fabrication of the flume, which will surely get a lot of use in our wet-lab facilities. We started with an idea, drew a few detailed schematics, purchased some materials, and started hammering away. We started with a sturdy floor in order to make the tank portable. Then we framed the walls, forming the 0 shape of the flume. At the moment, we’re covering the walls to make a smooth foundation for the fiberglass coating. Watch for progress updates in the following weeks.

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Fabrication

What’s brewing in the FABLAB? Nothing that’s going to revolutionize the world as we know it, but definitely something that will come in handy for our projects this fall. As you may know, sometimes it’s necessary for us to fabricate equipment in our shop facilities. In this case we are making a devise called a piezometer, which is commonly used to measure the flow of water through gravel in a streambed. A piezometer basically consists of a permeable standpipe with a hose attached to a vacuum pump. The pipe is driven in to the desired depth of the streambed, and the hose is used for drawing water out of the center of the probe. In fisheries, a piezometer is often used to measure flow and dissolved oxygen in spawning gravel. Intragravel flow can be determined by drawing a known volume of water under constant vacuum pressure for a given amount of time, as demonstrated in this YouTube video. Since gravel size, composition, permeability, and dissolved oxygen are substrate parameters affecting the survival of incubating salmonid embryos, a piezometer gives biologists the opportunity to measure these parameters directly, at specific locations without disturbing the sample site.