- Plan ahead.
- Measure accurately.
- Prepare the glass.
- Use the right adhesive.
- Apply the adhesive correctly.
- Install the glass so as to have continuous, bubble-free seams.
The only difference in building a larger tank compared to a smaller one, of say 55 gallons or less in size, is that the bonding process must be near perfect, and the glass thickness must be sufficient to withstand the added water pressure with a margin of error for the unexpected (i.e. Little Johnny winging his new Tonka truck at the Queen Angel in your tank in a fit of rage). You can find instructions and building hints in "DIY Glass Aquarium Plans"
Once the basics of construction are mastered, the biggest concern most people have with building their own custom aquarium is determining the right glass thickness. Using glass which is too thick means spending money you don't have to, and too thin means spending sleepless nights listening for the telltale sounds of cracking glass and running water. There are a few ways in which you can economize on the construction of your new aquarium with little to no loss in strength or utility, but first let's cover some important factors about glass.