>eggcrate with the poly tube "woven throughout"<
Hmmm...hadn't thought of that. I was planning originally on wrapping the 1/4" tubing around a big piece of 3" PVC. I evenually decided that was too complicated, and was just going to dump a bunch into my sump, or maybe in some of the IO bucket-style tank-return bubble arresters I use that have a lot of turbulent water motion in them.
>any ideas on life expectancy on that aluminum once buried?<
Don't really know. But have you ever seen a corroded aluminum can? I have the coils wired to zinc sacrificial anodes. In any case, the cost of the aluminum coils is not what I'm worried about, but the effort involved in digging them up would be a drag.
>I've been following some of the threads over on RC on this and the subject of using copper for the underground came up. I know the thought of copper anywhere near our systems is scary at best ....but do you think the trade off might be worth it...excellent heat exchange= shorter loop length =smaller pump. <
I considered it, but the aluminum coils are so cheap I think that's the way to go.
>Obviously the concern here would be a leak, but given a good quality tank side exchanger or a DIY thats built well, that risk would be minimal.<
Yup...it's a trade off. You need to decide if it's worth the risk. I think if you were using a tank side commercially available heat exchanger I'd be a lot less worried.
>I'm not saying it's a good idea just maybe an idea to kick around ....what about life of copper buried?<
Don't know how they would compare. Aluminum is a pretty inert metal. Copper turns green over time when exposed to air (reacts with oxygen), but it might do better buried?