Step #1: This may be the most dangerous part of the entire process: By purchasing approx. $800 worth of lumber, plywood and foam insulation at the hardware store there is a high likelihood of invoking the wrath of the wife. Beware!
Step #2: 4x6 lumber is expensive so I created my own 4x6 beams by screwing together two 2"x6"x12' for the beams. These elevate the ponds and allow me to adjust the slope of the pond so all the water moves towards the drain.
Step #3: create the frame of the pond with 2"x12"x12' lumber and lay 2x4 supports cross wise and on the inner perimeter.
Step #4: Add additional 2x4 cross-beams in the lengthwise manner as needed for support. Place the pond in its final position and begin painting all surfaces with deck stain. Upon retrospect this large 4x2 meter pond should have a 3rd beam running down the middle: will need to upgrade soon.
Step #5: Line the bottom with 1/2" or 3/4 inch plywood ( I used 1/2"). In this photo note the concrete blocks supporting the beams.
Step #6: Create upper support with 2x4's or 2x6's at the corners and in the middles to support the next course of 2x12's. I didn't like the brown stain color so I switched to black at this point.
Step #7: Line all inner surfaces with 1/2" or 3/4" rigid foam insulation.
Step #8: Cut-out approx. 15" dia. circle of the foam insulation where the drain hole will be.
Step #9: Install pond liner such as btl-24 with 4 to 6 inches of fold-over on top edge of pond wall.
Step #10: Install 1.25- 1.5 inch dia. bulkhead and plumb with ball valve for easy draining.
Step #11: Finally, install pre-stained 2x4's along the top perimeter of each pond.
