Pool Course Build Manual

Parts List

CAD Model: Full Mission Course

Obstacle Course Design Options

Both designs use the same hoops and have approximately 4-foot spacing between the hoops. This guide provides details on both designs.

Option 1: Suspended Design

Designed to be suspended from the swimming pool lane ropes.

Option 2: Pool Floor Design

Designed to be placed on the pool floor. This is a common design used at regional competitions.

1. It is recommended that all pipe joints be secured with self-drilling screws. Recommended screws are listed in the parts lists.

2. Pipe fittings with the potential to trap air should have drain/vent holes drilled with 1/4” or larger drill bits.

3. Pipe fitting specifications vary from one manufacturer to the next. The assembled sizes of structures could vary from the dimensions listed in this guide due to these differences. You may need to adjust the pipe lengths slightly as you construct the assemblies to ensure mating assemblies line up.

4. Anything requiring buoyancy needs to be tested and adjusted for the pool that the course will be used in.

5. Objects that must be lifted and transported have been weighed in air and in water. Weights may vary slightly in the pool that the course will be used in.

6. If the course is set on the pool floor, then it may be helpful to use weights on the platforms to keep the platforms from being moved by the ROVs during competition.

The obstacle course hoops are identical for the suspended design and the pool floor design. The parts used for the horizontal and vertical hoops are identical.

Assure that the PEX pipe is fully inserted into the bushing and bushings are fully inserted into the tee before securing with screws.

Obstacle Course Hoops Parts List

The suspension ropes are identical for the obstacle course and mission course.

See the Construction Tips page for suggested knots and visual knot tying aids.

Suspension Rope Parts List

Each obstacle course uses 10 suspension ropes. Each mission course uses 8 suspension ropes. The quantities in the parts list are for each suspension rope.

Mission Course Overview

The mission course is built upon two standard SeaPerch Challenge task frames. The frames were first used for the 2019 International SeaPerch Challenge and have been used as the foundation for the mission courses since then.

The course can be constructed without the task frames if desired; however, the task frames provide a stable base and are easy to attach other structures to.

Some elements of the mission course are reused from previous years to help reduce the cost and effort of building the courses.

Suspended Obstacle Course Frame Parts List

Pool Floor Obstacle Course Frame Parts List

This build guide includes instructions for building the obstacle course and mission course for the 2025 International SeaPerch Challenge. For the International Challenge, the obstacle courses and mission courses will be suspended from the pool’s lane dividers with the lower frames for the courses being approximately 5 to 6 feet below the water surface.

Regionals: Check with your local regional coordinator for information related to which courses may be used and any differences between the course described in this build guide and those used at your local regional competition.

Task Platform Frame

Two task platforms are required for the mission course. The two platforms differ only in the corrugated plastic platform base. Use following illustration as a guide to construct two task platforms. See the subsequent illustrations for the two different platform base plate details.

Use frame as guide to position cable tie slots. Cable tie slot dimensions are non-critical. Assure slot is large enough for cable tie. Punch or cut slots for cable ties. A large flat blade screwdriver works best for punching slots in plastic sheet.

Back Task Platform Base Plate

Front Task Platform Base Plate

Tape holes if using task platform base plates with 8 holes from previous years (shown below). White duct tape is preferred to cover the holes, but other suitable tape will work.

The blue tape around the small hole increases the visibility of the hole during competition.

Task Platform Parts List (quantities are for two platforms)

The Surface Vessel is used in the International SeaPerch Challenge as the start and stop area for the ROV. The Surface Vessel is designed to clamp over the overflow drain in the side of the pool. The Surface Vessel may not be used in local or regional challenges. If you are a regional host coordinator and intend to use the Surface Vessel, you may need to reconfigure if to work with your pool.

Surface Vessel Parts List

Overview

Bio-Buckets Installation

Bio-Bucket modification

The Hanging Coral is placed in one of the Bio-Buckets for the beginning of each team's run. If the Hanging Coral is lying on the bottom of the Bio-Bucket it will be difficult for the ROV to lift. The front end of one of the Bio-Buckets needs to be cut as shown.

Heavy duty scissors, sheet metal (tin) snips, or small hand saws can be used to cut the Bio-Bucket. Smooth any sharp edges using a file or sandpaper.

Attach two Bio-Buckets to the Back Platform.

Hoop Support Pipe Assembly

Bio-Bucket Hatch Installation

Attach the Bio-Bucket Hatch and Hoop Support Pipe Assembly to the Back Platform.

Back Platform Assembly

Coral Tree Parts List

Place the frame over the corrugated plastic sheet. Mark the locations of 6 cable tie slots as shown. The locations are not critical. Punch or cut slots for cable ties. A large flat blade screwdriver works best for punching slots in plastic sheet.

The red tape around the small hole increases the visibility of the hole during competition.

Deep Dive Platform Parts List

The Bio-Bucket Hatch is the standard mission course hatch that has been repurposed since 2019. The hatch supporting structure (hoop and support pipe) were used in 2019 and 2021 to orient the hatch in a horizontal orientation.

The hatch frame used in the International SeaPerch Challenge is constructed by gluing the pipe and fittings to create a sealed frame eliminating the need for additional flotation. When unlatched the hatch will open without assistance of the ROV.

Hatch Frame Construction

All pipes and fittings for frame are 1/2" Sch 40 PVC unless noted in illustrations.

Hatch Cover Plate Construction

Attaching Hatch Cover Plate

Center the frame over the cover plate. Mark the locations of 8 cable tie slots as shown. The locations are not critical. Punch or cut slots for cable ties. A large flat blade screwdriver works best for punching slots in plastic sheet.

Hatch Frame Parts List

Hatch Hoop Construction

The outside diameter of the PEX pipe may be slightly than the inside diameter of the 1/2" PVC pipe. It may take considerable force to insert the PEX pipe into the PVC pipe. Sanding or filing the end of the PEX pipe may be required.

Hatch Hoop Parts List

Hatch Support Assembly Construction

Hatch Support Assembly Parts List

Completing Hatch Assembly Construction

Deep-Sea Coral

The Deep-Sea Coral is the Sea Star used in the 2023 SeaPerch Challenge.

Assemble as shown.

• Painting is optional.

• Screws are not required for the pipe joints unless the pipe fits too loose in the fittings.

Maximum weights of Deep-Sea Coral: In air = 173 grams In water = 50 grams

Deep-Sea Coral Parts List

Small Octopus

The Small Octopus was used in the 2023 SeaPerch Challenge.

Construction Details

Cut four 18” pieces of the 3/16” diameter rope. Carefully melt the ends using a lighter, matches, or other heat source to keep the ends from fraying.

Connect the end of the 14” cable tie and leave approximately 1” of the free end sticking out of the lock. Trim the excess end.

Set 4 washers in the inside the drain fitting.

Hold the 14” cable with the round part of the loop in the drain fitting over the washers.

Feed the ends of a piece of rope over the 14” cable tie and through the holes in two of the washers and through the drain fitting.

Feed the ends of a piece of rope over the 14” cable tie and through the holes in the remaining two washers and through the drain fitting.

Feed the ends of the remaining two ropes over the 14” cable tie and through holes in the drain fitting. The ropes should line up between the outer intersecting edges of the flat washers.

Attach an 8” cable tie over the bundle of ropes and through holes in the drain fitting (as highlighted by the orange ellipse). Pull the cable tie tight to secure the ropes and the 14” cable tie. Cut the excess end of the cable tie.

Foam rod is used to reduce the in-water weight of the octopus and to help it stay upright. Attach the 3” long piece of 5/8” diameter foam to the 14” cable tie using two 4” cable ties.

Maximum weights of Small Octopus: In air = 148 grams In water = 50 grams

Small Octopus Parts List

Hanging Coral

Pipes may fit loosely in the 4-way furniture grade tee and may need to be secured using screws or glue. These Hanging Coral used at the International SeaPerch Challenge will be assembled using glue.

Maximum weights of Hanging Coral: In air = 118 grams In water = 34 grams

Hanging Coral Part List (quantities listed for two (2) Hanging Coral assemblies)

New Species

The New Species used at the International Seaperch Challenge will be painted as shown.

Use the "New Species Full Size Pattern.PDF" file provided below as a pattern for marking, cutting, and painting.

If using 0.06" thick sheet for the fin cut a single line as shown in the following illustration. If using corrugated plastic sheet for the fin, cut a slot wide enough to accommodate the fin.

Use the "New Species Fin Full Size Flat Pattern.PDF" file provided below as a pattern for marking and cutting.

The polystyrene sheet can be heated using a hot air blower and bent into shape. Use safety precautions when working with a heat gun.

Push the fin though the slit in the body. Cut the "flap" on both sides of the body as shown.

Attach two (2) washers on each side of the body using a cable tie. Cut the excess cable tie end.

Maximum weights of Hanging Coral: In air = 98 grams In water = 62 grams

New Species Parts List

Sea Sponge

Cut and remove the rope loop from the Loofah.

Wrap a cable tie around the center of the Loofah in the area that the string is holding the bundle of material together. Place the cable tie through the holes in four (4) flat washers and tighten the cable tie to hold the washers and the bundle of material together.

Pull and fluff the material around the washers.

Maximum weights of Sea Sponge: In air = 98 grams In water = 33 grams

Sea Sponge Parts List

The Sensors used at the International SeaPerch Challenge are made from red and blue PVC pipe. This is not required for regional competitions. Painting the pipe or applying high visibility tape will help with visibility if colored PCV pipe is not used. The sensors are color coded to indicate the sensing location in the mission course. The red sensor is to be placed on the Deep Dive platform and the blue sensor is to be placed on the main platform. Regional competitions may use a different color scheme.

Maximum weights of each Sensor: In air = 40 grams In water = 8 grams

Sensors Parts List

Sensor Tasks and Deep Dive platform options

The following illustrations show different options for for the sensor tasks if the mission course is setup on the pool floor.

In this option, the deep dive platform is not used, and the sensors can be placed in the openings of the center tees on the task frame. The tees should be taped or painted to identify the intended sensor location (red closest to pool side).

The course can easily be raised above the pool floor as shown. This may be helpful for pools deeper than 6' or for pools with sloped floors.

Another method of raising the course is to add floatation to the platform and anchor it using weights.

Knots for Suspension Ropes

Suggested loop knot. Start with 6-1/2" loop. Tie as shown. Tighten to form 4" long loop from knot to end when pulled tight.

Midline loop knot

Carabiner Knot

Suggested knot to fasten the rope to the carabiners.

Alternatives to Special Fittings

Special fittings such as 3-way elbows, 4-way tees, and 5-way crosses are used in the construction of the pool courses. These fittings save time when building multiple courses. The fittings are available from online vendors and "big box" home improvement stores.

3-Way Elbow Alternative

4-Way Tee Alternative

5-Way Cross Alternative

PEX to PVC Fitting Connection Options

Overview

Front Platform Assembly