This DIY project will show you how to make an awesome wooden air diffuser. This diffuser not only has more "bubble producing surface area (BPSA)" than several conventional 6" wooden air diffusers but also has less backpressure. Thus, when this air diffuser is used more air will be introduced into the skimmer and the bubbles will be smaller.

The air diffuser can be made from any size solid block of Basswood. The block used in this project is 2.5" x 2.5" which has the BPSA of nearly seven conventional 6" wooden air diffusers.

The first pic shows a black line drawn down the top surface of the block of wood. This mark will be used to later identify and align the panels.

From the block of wood cut (4) 5/16" panels to make (1) air diffuser. For the top and bottom of the diffuser use some 1/2" x 4" lumber. I had 1" x 4" pine on hand so I used it. The top and bottom of the diffuser should be larger than the diffuser to create about 1/4" lip around the entire perimeter of the air diffuser. This lip will allow a structural filet of super glue to be applied around the top and bottom of the air diffuser.

This next pic shows (4) panels, (1) top, and (1) bottom soaking in water. The cut wood must be soaked overnight to allow the wood to expand. Otherwise, the air diffuser will suffer structural failure.

Once the wood has been soaked it should never be allowed to dry out. This means that you will have to make them as you need them because they can not be stored dry after they are built.

Once the wood has soaked overnight, remove the wood and pat dry. Use the line drawn earlier to align the panels. The following pic shows the wood after it has been pat-dried and shows the panels aligned.

After completing the above steps the air diffuser is ready for assembly. Simply glue the diffuser together with super glue. Use medium viscosity (syrupy) super glue and accelerator. The following pic shows all (4) panels glued together and glued to the bottom. Notice how the black line is visible on the top edge of all four panels.

Once the air diffuser looks like the above pic, apply a structural filet of super glue to the interior of the four corner joints. Applying the super glue as if applying caulk makes a structural filet. Once the super glue is applied down the entire joint spray it with accelerator. I have found the easiest method for doing this is to tilt the box so that when glue is squirted into the top of the corner joint, the glue flows down the joint to the bottom. Once the glue reaches the bottom, level the box and spray the accelerator.

Do not follow the directions on the accelerator. Do exactly as these instructions say.

After all four corner joints have had a structural filet applied glue the top into place. Once the top is in place, apply a structural filet around the top and bottom of the air diffuser. Remember, the oversized top and bottom provide a 1/4" rim for this purpose.

This final pic shows the air diffuser after all of the gluing is finished. The only step left is to drill and tap the top for some type of hose barb, which matches the configuration of your skimmer.

The first time you use this diffuser make sure to lower the water level within your skimmer.

I have a six-inch diameter skimmer that stands about six-feet tall. I have two types of pumps. I have a linear piston pump made by www.medousa.com Also, I have (4) Tetra luft pumps that I have enclosed in a sound proof box. I don't use both pumps at the same time.

When I use the Medo pump in conjunction with the DIY diffuser(a larger version), I get about two-feet of dry foam. However, the pump is very sensitive to line voltage, or something, and it overflows the skimmer almost daily due to the volume of air being produced cycling.

Currently, I have the four lufts hooked up to my skimmer. They produce about 1/10 the volume of air as the Medo. The skimmer works fine like this and the air volume produced does not appear to cycle. However, I like the way the skimmer works with a lot of air and am currently looking for a good high volume pump.

If you are in the market for a good pump, look into Gast Manufacturing, www.gastmfg.com

This company sells Gast pumps: www.aquaculture-supply.com

The Cyanoacrylate and accelerator can be purchased from www.usagoldca.com . The glue is part number 704 or 705. The accelerator is part number 708 and 709.