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This is not a step by step tutorial, more for inspiration and general information!

My very first DIY stand was a 100cm two-door home-depot plywood stand. It looks fine in pictures, but was NOT up to the insanely high, unhealthy standards of excellence that I hold myself to with everything:



No journal for this old tank.

The lesson here was: don’t use home depot plywood! It sucks. Find a real plywood dealer and spend the extra $.

My next stand was way more ambitious: a 150cm x 60cm stand, designed to hold up 2400+ lbs, made from quality baltic birch plywood. 3 doors, two interior weight-bearing vertical panels, adjustable leveling feet. It worked great, and can be seen in my two journals Many Lessons and Inert Sand Trials:


I did a WAY better job on this stand, and it now resides with @Kwyet ! Also, a spray finish really makes a big difference.

After that, the 90cm Experiment Tank stand. Two doors, and instead of a cumbersome middle panel, I used one hefty plywood column:


Scottish accent Fookin' crispay



This tank also had a waterproof, sealed bottom “rim” so up to 2cm of water would have to fill the stand bottom before it overflows. Useful for emergencies or leaks, when combined with loud water leak alarms! This stand and tank is in my garage, soon to be sold to anyone in Colorado who wants it!

The new 120cm stand:​

This stand is for my new 120cm tank! This stand is the culmination of seven years of stand-making. All of my mistakes, lessons, preferences, and skills were combined to make the stand of my dreams!

And of course, I had to move homes and got seriously injured, requiring surgery, while I was trying to finish it. Sorry for the lack of pictures!

I would not say this design is beginner friendly. It’s not expert, but likely intermediate difficulty. I have a Wen track saw and a Sawstop PCS Cabinet saw, which changes the entire process compared to someone working with more difficult tools. I also have a Graco Magnum X7 paint sprayer for a professional paint finish.

First, I started with mocking up the stand in Shapr3D, my modeling program:


My local lumber company had really good deals on 5x5’ sheets of ¾” baltic birch plywood.

IT IS CRITICAL for precision woodworking like this (no trim to cover up mistakes) to get exact measurements, particularly for the thickness of the plywood. For example, using a pair of digital calipers, this 3/4" plywood was 17.8mm thick (0.7 in a lot smaller than .75"), which is what I used in my modeling program to create the exact length of cuts to properly span 120cm long and 60cm deep.

I collected the exact measurements of each part needed, and threw it into Opticutter to determine how to best cut my 5x5’ plywood sheets:


You don't need to study these sheets; the photos are just to show you how Opticutter works to save you from creating too much waste, and using the fewest cuts!

Steps I followed for this stand:​

1. Cut all panels using table/track saw.
2. Make 4-ply support column. Make notch cut ~145mm from top of column to fit behind front brace. Glue and trim/clean.
3. Cut out "access holes" in panels, including pocket holes for front and back brace, predrilled holes for front brace (in middle, and upper portion for future front panel) and predrilled holes for back panel. Use a router with roundover bit to create round, smooth holes for cord and tubing access, as well as handles for moving the stand around!
4. Run the "standing height "of the side and back panels (and 4-ply center column) through table saw to make uniform height for all 4 parts. All of these 4 parts should be cut to the exactly same height.
5. Trim door “finger-pull” with a router. Just a 45-degree "slice" off the door's corner to make a finger pull.
6. To assemble: Flip top upside down, test fit sides and back, secure with screws. Make front edge flush, back can be trimmed down with router flush bit if necessary.
7. Attach the bottom panel, Make front edge flush, as the back can be trimmed down.
8. Add 4-ply column, ensure front edge flush.
9. Add front and back "braces".
10. Add front panel, and bottom "lips" that hold any spilled water in.
11. Spray and sand stand, fill gaps with Bondo wood filler. Sand and repeat until corners, cracks and divots are smooth.
12. Caulk the inner corners where water would be.
13. Paint stand and doors.
14. Attach doors.
15. Add feet.
16. Run electrical and LED strips.
17. Cut foam mat to size.

Here's some of the steps in the modeling program:


4-plywood-thick center column, with "notch" for the front brace to fit flush:


Top down first on a flat, even surface, then add sides and back:



Flip right-side-up, and add the bottom panel:



Add the rear brace, the front brace, and the center column. Make sure the front brace and column are flush with the front of the top/back panel edges.


Add the front panel and bottom lip pieces:


For the doors, create a notched finger pull (side view):


Door hinge stuff:

• Blum Clip top Blumotion Full Overlay, 110° euro style hinges
• Kreg hinge jig

And it's done! Here's some of the few pictures I DID take of this process, sorry! I had a lot going on:

Gluing the 4-ply-thick center column:


To make the access holes in the back and side panels, I 3D printed some plastic guides for my router bit to follow, then roughly cut the inside out so the router had less material to work through:


Perfect routered holes:



I learned to score the plywood with my box cutter first, so when it chipped from the rough jigsaw cut, it chipped ONLY to the scored lines:



I removed the excess interior material with the jigsaw, then routered. I also used a roundover bit (in process on the left hole, right hole not rounded):

Any chips or imperfections could be fixed later with bondo wood filler and sanding.


Once I had my access holes cut out, I could assemble! I used clamps to hold the panels together and flush, used an Incra T-Rule (amazing device) to mark a line that was the middle of my plywood panel's core:



Then, I drilled countersink holes with this bit for the screw heads to sit below the level of the wood:



Screws:
Since the screws on the top, bottom, and rear of the stand would never be visible, I decided to skip the annoying "pocket screw and glue" scenario and just go with crazy robust torx-head 1.5” construction screws. I LOVED it. Definitely my preferred method, though they really do require pre-drilling AND drilling countersink heads. Still, way stronger than pocket screws my god.

• SPAX #8, 1-1/2" Interior Flat Head Torx Wood Screws
• INCRA T-Ruler 6 inch for marking my ~8.9mm line (middle of the plywood core I was screwing into).

Wood filling and Priming:
Bondo wood filler is amazing stuff. I used TONS of it, this was just the first pass:

Apply, sand, apply more, sand more.


Then I primed with Sherwin Williams Gallery Series primer, and sprayed with a TrueAirless 515 tip in my Magnum X7:


Once the primer was dry, I sanded it, and sprayed again. Once dry, sanded again. Lots of sanding:



I wiped the tank down with tack cloth, then went for the finishing coat using a Graco FFLP 310 Tip and Sherwin-Williams Gallery Series Waterborne Topcoat in true black. Probably a matte or satin sheen, I can’t recall. Not cheap, good paint! Make sure to filter your paint through a find mesh before spraying.



By far the best, most perfect finish I've ever had on a stand. BTW, the doors are fully adjustable up, down, left and right to get them nicely aligned. Blum hinges rock!



Once it was all put together, I got some help to move it into the new house. And installed the oversized Aquarium Mat.

I paid Tommy, the owner of Aqua Rocks Colorado, a delivery fee to have my custom 120x60x50cm tank delivered and installed on the stand. Once positioned evenly around all sides, I trimmed the aquarium mat with an Xacto knife, and was finished!

I'm tired today, but I'll upload more pics of this stand soon to this thread and to the 120cm Journal, too!

Questions? Ask below! I love to help out.​