(...) homemade trays, (...) weigh a tonne, they leak and they take up huge amounts of space.
Either ABS or Plexiglas trays are easy to fabricate. I'd forget plywood - more work to end up with way more weight. By the time you add up the
cost of marine ply and penetrating epoxy, you'll have spent more than just going out and buying the Cesco trays in the first place.
Heat welding of plastics is quite different than solvent welding. I wanted my own sink made out of something chemically inert and decently insulating, so I chose thick polypropylene sheeting. I was fortunate enough to know someone who specializes in welding lead sheets together inside new nuclear reactors. So he had the needed equipment and skills, and he
did the whole job dirt cheap as a kind of horse-trading favor. It would cost a small fortune to hire someone to do that kind of thing. It's quite a specialized skill set. Solvent welding,
on the other hand, is very easy. Lots of plastics shops teach courses in this. Slightly scuffed plexi or ABS sheets can be had cheaply. You need a very straight square edge. In the old
days, we'd saw the sheet with a fine plywood or plexi blade then dead-square the edges with a laminate trimmer. Nowadays most people simply make a single cut with a Festool rail saw
and a plastic blade and go right to the gluing step. I've even made very complex darkroom projects like archival print washers in a single afternoon. It would be even faster today.
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