Things You'll Need
- Inch-thick plywood sheets
- Table saw
- 2-inch wood screws
- Wood glue
- Drill with Phillips screwdriver head
- Two-by-four lumber
- One-by-two lumber
- Routing table
- Wood putty
- Sand paper
- Paintable silicon sealant
- Marine paint
- Wood paint
- Plate glass cut to size by a glass company
Instructions
Cut the plywood to the dimensions of your aquarium. Cut a piece for the back, the bottom and the two sides, and make sure your cut is as clean and straight as possible to reduce the amount of sealant you must later use.
Attach the back panel to the bottom panel so that the bottom of the back and floor piece sit flush. Apply wood glue to the seam, and reinforce the joint with wood screws every four inches. Use a drill to countersink the heads of the screws at least 1/8 inch below the surface of the back.
Attach the side panels to the base and bottom construction, so that their bottoms sit flush with bottom of the floor panel. Use wood glue and countersink screws to secure the joint.
Cut the two-by-four to the same length as the back panel. Using the routing table, cut a channel the width of your piece of glass 1/4-inch deep down the center of the two-by-four. This piece will support the glass on the lower front of the aquarium.
Affix the glass support to the floor and sides, pushing it flush against the front edge of both, so the groove you cut in the previous step is exposed on its top edge. Use wood glue and wood screws to fasten the joint.
Measure the remaining height from the top of the two-by-four glass support to the upper edge of the aquarium sides. Cut two pieces of one-by-two lumber to this length. These will secure the glass on the sides of the aquarium. Cut another piece the same length as the two-by-four used to secure the glass on the bottom edge, minus 2 inches. This will cap the glass on the aquarium's front.
At the center of one of the wide edges of the one-by-twos you cut, use the routing table to cut glass-width channels 1/4-inch deep.
Attach glass support pieces to the sides of the tank so that the channels cut by the routing piece line up with those cut on the two-by-four glass support. Use screws and wood glue to secure these joints.
Apply wood putty to cover the holes on top of the countersunk screw heads, and allow for the glue to dry.
Apply silicon sealant to each joint inside the aquarium, including the joints where glass supports connect to the structure. Allow sealant to cure before moving onto the next step.
Using marine paint to paint every wood surface inside the aquarium, including the glass cap piece created in Step 6.
Slide the glass into the channels in the glass support, and affix the glass cap piece created in Step 6 to the top. Use silicon to seal the edges. Allow silicon to cure.
Fill the tank with water to check for leaks. If any are identified, apply additional sealant and re-paint the joint.
Paint the exterior of the tank using wood paint.