i harvested this and the next post from this echo years and years ago... i   
   have no idea who the original author is/was... that aside, i guess it is time   
   to post it again...   
      
   ==== Begin "plytank1.txt"  ====   
      
   How to build a 100 and a 240 Gallon Plywood Aquarium Tank   
      
   Your first step is to assemble all of the materials listed on the materials   
   sheet accompanying this article. When buying plywood, it is recommended that   
   you purchase it from a lumberyard that also has a good mill shop. Unless you   
   are unusually talented in woodworking or cabinet making, it is not advised   
   that you cut your own lumber since the bottom and end sides must be cut very   
   accurately. Any irregularities from end cutting will present serious problems   
   when the aquarium is assembled.   
      
   The tank must first be assembled using the finishing nails to hold it together   
   while drilling the screw holes. The 100-gallon tank can be put together by one   
   person, but the 240-gallon will require two people due to the bulk and weight.   
      
   Start the construction by selecting the bottom of the tank. For the 100-gallon   
   tank, this is the 21" x 46-1/2" piece, or for the 240-gallon, this is the 24"   
   x 94-1/2" sheet. Stand the bottom on edge and make certain that the "A", or   
   good side, is placed on the inside of the tank. Take one of the pieces for the   
   side, place it over the edge of the bottom, and secure it with two or three   
   finishing nails. In order to allow for easy removal, do not drive the   
   finishing nails in all the way. Make absolutely certan that the pieces are in   
   perfect alignment. When this has been completed, repeat the process for the   
   other end piece.   
      
   Next, take one of the 24" x 48" pieces and place it over the partially   
   assembled bottom end. Line it up and secure it in place with the finishing   
   nails. Do not drive the nails in all the way. Repeat the process on the other   
   side. You now have two strips of plywood left. These pieces are 48" long and   
   will have to be cut so that they are also 46-1/2". The accuracy of this cut is   
   not important and can be done at home. Square it up and fit it inside the top   
   lip of the tank. Repeat this process on the other side.   
      
   Now draw a straight-line 3/8" from all edges on both sides and the bottom side   
   of the end. Then, starting from about 2" from the end of all the lines, make a   
   pencil mark every 3". This mark will be where the screw holes are drilled. At   
   most lumber companies and discount stores you can buy a drill with a   
   countersink attached. Ask the clerk to provide you with the proper size for a   
   #10 screw. If you cannot find a drill with an attached countersink, it will be   
   necessary to buy a separate one. This should not be necessary, however, since   
   the combination unit is readily available. Once obtained, drill all the holes   
   that you have indicated with a pencil mark. Do not drill too deeply. The head   
   of the screw, when set, should be approximately 1/16" below the surface of the   
   wood.   
      
   Mark the sides so that the tank can be put back exactly as it was, then   
   disassemble the unit. Shake out the sawdust and sand off any irregularities   
   caused by the drilling. Do not over sand and change the contour of the wood.   
      
   Mark the sides so that the tank can be put back exactly as you assembled it   
   before, paying attention to your assembly indicator marks. This time, however,   
   a bead of Elmer's waterproof glue is applied. The finishing nails can now be   
   driven in all the way and the tank screwed together. It is very tiring and   
   slow, tedious job if you are using a standard screwdriver and not an electric   
   drill with a screwdriver attachment. The screws are staggered between the   
   2-1/2" and 3" length screws. Start the row with a 2-1/2" screw and then   
   alternate. Be sure the tank is perfectly aligned before completing the final   
   assembly. Wipe off the excess glue before it hardens.   
      
   Once the glue has hardened, the next step is to cut out the front for the   
   insertion of the glass. It is only necessary that a 2-1/2" lip be left on the   
   front side, so draw lines in 2-1/2" from all sides. If you desire rounded   
   corners, use a soup can in each corner and draw the necessary curve. Drill a   
   hole on the inside of the line of sufficient width to allow the insertion of a   
   saber saw. Go slowly and cut out the front of the tank. Don't force the saber   
   saw by going too fast--taking your time will result in a nice, even cut. Have   
   someone hold up the plywood as you complete the cut to avoid the weight of the   
   inside panel tearing the lip. If you didn't make the cut as even as you would   
   like it, now is the time to sand it down and improve its appearance.   
      
   On the cut ends of the plywood, there will be gaps of holes inherent in the   
   manufacturing of this product. Fill in these holes whenever noticed using   
   plastic wood. When dry, sand the filled edges to a smooth finish. Shake all   
   the sawdust out of the tank and dust it carefully. A vacuum cleaner hose with   
   a brush attachment makes the job easier. You can finish the fine dusting with   
   a tack cloth just prior to painting the inside.   
      
   The best paint found is Pratt & Lambert, which is readily available. Be sure   
   to get Gloss Activator since it produces a much better finish for this use. Do   
   not use any paint that does not require the mixing with an activator. There   
   are paints that don't require mixing which have the word "epoxy" on their   
   label, but they are totally useless for this type of work. You must use an   
   epoxy paint that utilizes an activator, or catalyst.   
      
   When mixing, follow the directions and mix only enough for one coat. Once the   
   paint is mixed, it cannot be stored and must be used within a few hours. It is   
   only necessary to paint the inside and the edges with epoxy unless you want   
   to--it is only a waste of money. After painting the first coat, allow the tank   
   to dry for 24 hours, then re-coat. Some aquarists use only two coats. However,   
   three coats are preferred. The latter would be necessary if you were going to   
   use the tank as a marine aquarium. The 1/2-gallon of paint is enough for three   
   coats.   
      
   After the final coat of paint is dry, many aquarists put a light beading of   
   silicon aquarium sealant in all corners. In most cases, this is not necessary   
   but applying it will serve as insurance against leakage, should there be a   
   bubble or crack in one of the corners.   
      
   The final step is the insertion of the glass. Cut the end of the silicone   
   sealant spout to its widest opening. Place the tank with the cut side down and   
   run a continuous bead of silicone aquarium sealant all around the lip. Center   
   the silicone beads so that they are about 1/2 way between the edge and the   
   sides of the tank. Take the glass, tilt it and set it on top of the silicone   
   bead. Press it firmly down on all edges. It is a good idea to take a couple of   
   pails of water, or other weights, and set on top of the glass to keep pressure   
   on the silicone beads until they are set. Let it cure for a few days, then   
   remove the weights. Trim off any excess silicone sealant and test the tank.   
   This is accomplished by filling with water. If no leaks appear then drain, the   
   water and you can put the tank in service. Should any leaks occur--an unlikely   
   occurrence--a little silicone aquarium sealant will quickly seal it.   
      
   If the aquarium is to be used in the basement fish room, a coat or two of   
   latex paint will be satisfactory for the exterior. If, however, it is to be   
   used in a more formal setting, the tank can be faced with stained or varnished   
   paneling or other desired finish.   
      
   This is an economical way to acquire a large tank. Given proper care, the life   
   of your new tank should be a lengthy one. I have 100-gallon tanks that were   
   built 20 years ago and are still in service!   
      
   ==== End "plytank1.txt" ====   
      
   )\/(ark   
      
   Always Mount a Scratch Monkey   
      
   ... In a sense, we have always lived in Ahnk-Morpork.   
   ---   
    * Origin:  (1:3634/12.73)