I've been working on this a couple weeks now and have been updating a tread over on reef2reef for this tank. I am finally getting around to posting it here.
I started out with some scraps from some left over projects and a small fountain pump I had laying around from an older tank. The result is about 3 gallons of total water volume. I started with these plans and made some changes along the way. First, the got rid of the fuge area. The back was just too small for it and probably not really necessary. Second, I swapped the sides the overflow and return are on. As far as dimensions, everything stayed the same.
The main reason for this tank was as an entry for the Reef2Reef Nano in 90 competition. Check out my thread there too.
http://www.reef2reef.com/forums/nano...nano-90-a.html
Next I pulled out the old acrylic bender and bent the piece that is used for the front and sides of the display area.
After this I cut the acrylic to the correct length and height. This is a trick I picked up from the shows Tanked and Fish Tank Kings. I always noticed they cut after shaping the acrylic. This is because when the acrylic is bent the ends will pinch out creating an unlevel surface. Cutting after shaping removes this area. I also started attaching the displays back wall, and the filter sides, weirs and back. I also drilled the hole for the 1/2" bulkhead before attaching the back. Would have been really hard to get it in there with the front and back already on there.