Things You'll Need
- 3/4" AC Exterior Plywood Sandpaper (medium and fine grit) Measuring tape Pencil Wood screws or drywall screws (Phillips head) Drill Countersink drill bit Phillips screwdriver bit Waterproof wood glue 1/4" plate glass -- 94" x 16" Xylene glass cleaner Commercial glass cleaner (e.g., Windex) Silicone aquarium sealant Auto body putty with hardener Putty knife Two-part marine epoxy paint Paint brushes
Instructions
Building the Tank
Cut the plywood to size for the nine tank pieces as follows: bottom - 24" x 8', back - 16" x 8', sides (cut 2) - 16" x 22.5", horizontal front panels (cut 2) - 3" x 8', vertical front panels (cut 2) - 3" x 10" and top brace - 12" x 22.5". Sand any rough edges with medium grit sandpaper.
Label one side of each panel clearly as the outside (e.g., by drawing a large "X" from corner to corner).
Drill from the outside to create screw holes along the long edge of the bottom panel. Space the screw holes every 2-3" along the length. Apply wood glue liberally to the inside of the panel in a 1" wide strip along the freshly-drilled edge. Screw the back panel to the bottom panel so that the bottom panel supports the back panel along the long edge. Wipe away any excess glue.
Drill from the outside to create screw holes along the short edges of both the back and bottom panels. Space the screw holes every 2-3" along the length. Apply wood glue liberally to the inside of all three panels in a 1"-wide strip along the freshly-drilled edges. Screw the side panels to the back and bottom panels so that the bottom panel supports the side panels. Wipe away any excess glue.
Drill from the outside to create screw holes along the front edge of the bottom panel. Space the screw holes every 2-3" along the length. Measure 3" up from the bottom of each side panel and make a mark at this height on the front edge. Drill from the outside to create three evenly-spaced screw holes in the lower 3" of the front edge of each side panel. You will use these holes to attach the lower horizontal front panel.
Measure 3" down from the top of each side panel and make a mark at this height on the front edge. Drill from the outside to create three evenly-spaced screw holes in the upper 3" of the front edge of each side panel. You will use these holes to attach the upper horizontal front panel.
Drill from the outside to create screw holes in the center portion of each side panel. Space the screw holes every 2-3" along the length. You will use these holes to attach the vertical face panels.
Apply wood glue liberally to the inside of each side panel in a 1" wide strip along the freshly-drilled edge. Apply wood glue to each end of each vertical front face panel. Screw the lower horizontal face panel to the bottom panel so that the bottom panel supports the face panel along the long edge. Screw the lower horizontal face panel to each side panel. Screw a vertical face panel to each side panel, so that the vertical panels rest on the lower horizontal face panel. Screw the upper horizontal face panel to the side panels so that the horizontal panel rests on the vertical panels. Wipe away any excess glue.
Allow to dry thoroughly, according to the manufacturer's recommendations on the wood glue.
Painting the Tank
Paint the entire tank with a thin coat of marine epoxy. Paint all sides of the top brace with a thin coat of marine epoxy. Allow to dry thoroughly, according to the manufacturer's recommendations on the epoxy.
Sand the tank and top brace with medium grit sandpaper, then fill any holes or uneven spots with auto body putty mixed according to the manufacturer's directions. Allow to dry thoroughly, according to the manufacturer's directions on the putty.
Sand the tank and top brace with medium grit sandpaper, then apply a second thin coat of marine epoxy and allow to dry thoroughly, according to the manufacturer's directions on the epoxy. Repeat with a third coat of epoxy paint.
Sand the tank and top brace with fine grit sandpaper, then apply a fourth and final thin coat of marine epoxy and allow to dry thoroughly, according to the manufacturer's directions on the epoxy.
Installing Glass and Finishing the Tank.
Turn the tank onto its front. Sand 2" of the inside of the front panels around the glass opening.
Clean both sides of the glass thoroughly with xylene glass cleaner and allow to dry. Clean both sides of the glass thoroughly with commercial glass cleaner (e.g., Windex) and allow to dry.
Apply a liberal coat of silicone aquarium sealant to the sanded portion of the front panels so that you have a 1/2" wide bead of sealant approximately 1" away from the opening on all sides.
Install the glass so that the bottom rests on the bottom tank panel for support. Press firmly on the edges of the glass panel to remove any air pockets that might cause leakage. Allow to dry thoroughly, according to the manufacturer's recommendations on the silicone sealant.
Seal around the edges of the glass and along all inside seams with silicone aquarium sealant. Allow to dry thoroughly, according to the manufacturer's directions on the silicone sealant, before turning the aquarium upright.
Drill from the outside to create screw holes in the center 12" portion of the upper edge of the back panel and upper horizontal front panel. Space the screw holes approximately 2-3" apart. Apply wood glue to the ends of the top brace. Screw the top brace to the upper front and back of the tank frame. Allow to dry thoroughly, according to the manufacturer's recommendations on the wood glue.
Apply silicone sealant around the edge of the front frame opening on the outside of the glass and allow to dry thoroughly, according to the manufacturer's recommendations on the silicone sealant. If desired, cover screws with auto body putty and paint with epoxy paint. Allow to dry thoroughly, according to the manufacturer's recommendations on the epoxy, before filling with water.