I've destroyed my eyes trying to read all of this....
, but am glad it's out there, thanks Stinkbud!
I've been working on designing a 4 rail(5x5 fence,48"L), 6 sites( 8" spacing) per rail system, run off appx 30 gal res( 54 gal rubbermaid) running 2 400gph pumps plumbed into a common manifold, feeding 4- 48" runs of 1/2" pvc which are going to be mounted outside the rails and will each feed 7 ezclone 360 sprayers through 1/4" irrigation lines. So pretty much a doubled up flower unit rather than 2 separate. I'm running dual pumps in the big res so I can have one type of pump only( 400gph) throughout all the systems for easy of swapping/replacement. I'm running my 1/2" pvc feed lines outside the rails only because I think it will make cleaning and maintenance easier..I'm still trying to figure out an easy way to make the end caps seal AND be easily removable..one thing at a time..lol
It's sounds like you put a lot of thought into your new system. I'm exactly the same way bro! I like thinking...in fact I think people should try it more often, especially politicians. I like the idea of using two pumps especially if you can make the whole system redundant. That way if one pump goes bad you still have the other one to keep the plants alive long enough for you to fix it. My buddies pump went out last week and he lost all his plants but one. That's the thing with Aeroponics, you really need to be around to make sure things are working. I've always had just a small closet grow that's easy to stay on top of. If I don't hear my sprayers coming on for a few minutes I'm all over it. Of course it's rarely an issue but it is reassuring (and calming) hearing the water.
My first system (store bought) used external plumbing w/hoses feeding each sprayer. A PVC pipe ran lengthwise and little black hoses were attached to fittings on one side and the sprayers on the other. So why did I change to internal sprayers? Leaks! When you run everything external, one drip will drive you nuts. Even the smallest leak will cover your grow room floor with water. I had 14 plant sites with a sprayer on each side for a total of 28 sprayers. With the hose type assembly you have 28 connections X3 to deal with. There are potential leaks everywhere, fittings, hose connections, sprayers, etc. If you do end up with a even a small leak you'll wake up to a drained res and water everywhere.
That's why I came up with the internal spray assembly. Only one connection point per sprayer and even if it did leak, the water only has one place to go, inside the rail. Maintenance is also a lot easier. You can take the entire spray wand out and rinse it off in one easy step. I designed my system so that as long as the end caps are sealed it is impossible to flood your home. Of course I say that but the truth is, there is a stoner out there bound and determined to flood the shit out of everything no matter what I say!
Which reminds me...always use a hand spray wand on your garden hose that requires you to hold it down when you are filling your res with water. That way when the phone rings you have to let go and stop the water or at least stand right there watching it fill up. Trust me on this people... LOL
On to the end caps, the only place you can have a damaging leak if you do it wrong. I've used window seal, silicon, tape, you name it and I've tried it. That's why I use 2 applications of 5-min epoxy on the caps. The first on the inside, then I stick the cap on. After the first application hardens I put another layer on the outside and make sure the epoxy fills all the gaps. The other end is always left unattached so you can clean and rinse the rails after each harvest.
Make sure you think about some sort of Scrog method. I use two layers of 4" netting. Some people think the screen is there to support the plants (which it does) but it's actually a lot more important for training your plants. To maximize your harvest you need to increase the budding sites on each plant. If you super-crop your plants and keep training them down, you can significantly increase your harvest. The goal is to fill every square inch of the grow space with bud sites but keep the whole grow canopy only a couple of feet thick.
Fuck, now I'm talking too much again! Anyway, good luck with the grow bro. Be sure and post photos or even think about starting your own thread. That's how it all began with me...