A rare behind-the-scene insight into Eric koi filter production.

As already mentioned, all Eric filter units are hand-made to order and Jason and Danny fabricate the outer carcasses at JBR Plastics Ltd.

9mm thick polypropylene sheets being welded together by heat gun

This shows the 9mm thick polypropylene sheets being welded together by heat gun and polypropylene welding rod.

Although it’s not shown on the shot, all the internal polypropylene fixtures are welded into place before the outer box is finally assembled.

These internal fixtures comprise of the brush box retainer, the perforated transfer wall, the two 4” diameter polypropylene sockets, the outer bottom frame supports, the cartridge tracks, the end sheet tracks, the circular end baffle and the external threaded nipple for water pump connection, which can either be 1.5” or 2”.

The standpipe and the brush box are also fabricated by JBR

The standpipe and the brush box are also fabricated by JBR 2

The standpipe and the brush box are also fabricated by JBR.

After each carcass is completed it must then filled with water to ensure no leaks are present.

ERIC Koi Pond Filter Being filled with water to test for any possible leaks

Whilst all this is going on, some 20 meters away over at Rose Cottage, the cartridge blocks need to be made up – usually by me, believe it or not – I love making up these blocks – however, you should hear the language when I complete a block and check it to find I’ve missed a washer out!

Making the ERIC Mat Cartridges

Making the ERIC Mat Cartridges 2

Making the ERIC Mat Cartridges 3

The carcasses are then carried from JBR to Rose Cottage where Ian Miles fits the powder-coated steel support frames which are made and delivered by Mark – yet another Eric aficionado who uses them on his own Koi pond.

The bottom frame simply sits on the external supports whilst the top frame is drilled and secured firmly with waterproof bolts.

The ERIC frame is drilled and secured firmly with waterproof bolts.

As you can see from the photo, Ian Miles has already started fitting the aeration lines. Ian has a jig for each model that is placed against the unit so the entry holes are correctly marked out for drilling. This enables him to assemble the entire outer manifold and slot it as one single piece through the pre-drilled holes.

ERIC Koi Pond Filtration and Aeration being fitted by Ian Miles

The fittings used for the ERIC Filter aeration

Words here about the aeration assemblies, all pipe work and fittings used are to 3/8” UPVC solvent-weld pressure specification.

Depending on the size of the model there are tank connectors, a threaded hose adaptor, tee-pieces, plain elbows, plain/thread elbows, plain/thread sockets (to connect and be able to disconnect the air bars) and of course, the air bars themselves complete with end caps.

Believe it or not there’s eight meters of 3/8” pressure tube required to fit out a single Eric Four unit!

Once the aeration assembly and air bars have been fitted, the end sheet, the EricMat blocks and the brush box simply slot into place.

The ERIC Brush Box and Cartridges are placed into the ERIC

The standpipe is then placed in one of the 4” sockets and the two very important 4” to 115mm rubber boots are placed inside next to it.

This is how the units look at this stage.

ERIC units almost complete without lids

Next follows the hinged lids and the owner’s personal name plates can now be riveted on as shown.

Personal name plates for each ERIC owner

The final part is dusting and wiping them down in readiness for transportation – black polypropylene attracts and collects dust just for fun!

ERIC Koi Pond Filtration units ready to be shipped to customer

By the way, just trust me, these units are ‘flipping’ heavy!

ERIC units being loaded into van

If you would like to talk about any of this, please feel free to visit the ERIC Pond Filters forum!


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