Stealth Grow Cab Redesign-Heat Issues

After 2 fun grows, it's time to rethink. The number one issue I have had to deal with have been heat.
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A total rethink of supply and return air was in order...or do away with HPS and go something like the dreaded LED for NO other reason than heat. If it wasn't cooking the reservoir and providing be with root rot it was driving temps in excess of 90 deg I've dealt with it all in the last year. Three 2' 4 bulb T5's and a 400 watt HPS create a LOT of heat, and in my opinion, these jokers selling a few muffin fans simply aren't going to do it.
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This is what I have to work with. The unit is a downflow, exhausting into an insulated box containing the inline fan, then into another box when flowering, and bypassed during the veg cycle. The second box has a carbon filter in it allowing me to "pull" through it without having to have it located in the precious space of the grow cab. Designing an air system that removes the heat from the proper areas, and being able to have an exchange rate required to combat the heat in both the upper and lower chamber has been a real chore. This redesign using the same fans as before has lowered cab temp by an honest 7 deg. Here is how I did it.
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This is the bottom plenum as well as base for the Baby Bloomer Ebb and Flow unit.
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Here are the sheet metal side panels that will tie into the white plexiglass plenum/base.
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Here is the left side of the grow cab after I removed the soundproofing insulation from it. This is where the side panel will fit. Break out the trusty rusty sheet metal snips and go to work
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This is where the side returns will tie into the main return located under Ebb and Flow unit
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This is where the 400 watt HPS lamp fixture will exhaust as well as the upper cloning room
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This is where I tied the left and right side of the cabinet into the main return (passive) plenum. Foam tape and HVAC Clear Silicone was used to airtite all connections
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This shows how the upper cabinet and light hood connect
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This is the right side of cabinet. Note location where the 4x12 register is cut. This is no accident, as is vents air at the plant canopy and below where we dont want heat to build up
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Here's a close view of the clear plexiglass transition I made. No reason for clear, I just had scraps but it does give kind of a "cool" effect, and better yet they really work!
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This is where the power from the fan and ballast wiring lead into the cab from underneath house
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Nice and sealed and only takes about an extra minute to do it right. Shortcuts = problems
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Cab is complete.
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This view shows right side of cab. Note white louvered return grill. Timer handles lighting and timer functions for Baby Bloomer in lower flowering area. The T-5 lamp is being used until these little ladies (I hope) can handle the 400 watt HPS located above it. I simply remove the T-5 when they get about 6-8 inches tall.
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Here you can see the 1/2" lines leading to the cabinet housing the 1/15th HP chiller. This locking cab also houses my nutrients and test equipment
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It was a tight fit, but it fit as if it were made to fit. Smile!
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Here's a view of the chiller located next to grow cab. Nice to not boil my reservoir anymore!
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Well, it was a fun mod, and it worked without a hitch. This grow should prove much smoother with a helluva lot headaches. Wish me luck and I hope you enjoyed
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