If you use the correct acrylic, tools, and fabrication technique, you have nothing to worry about. Just make sure you have a nice, smooth, flat edge on the acrylic and use the Pin method with weld-on 4. I doubt anyone that has done it that way has run into problems. I have made a 15 gallon sump, 25 gallon refugium, and 90 gallon display tank. Using the pin method, I got beautiful seems with no bubbles.

I agree with mark though...if you can get a rubbermaid tub to work, do it.  But if you have size restrictions under your tank or want it a certain dimension to maximize your space....and have some extra time and money to spare, then acrylic may be what you need. Also, doing baffles in a rubbermaid tub is tricky!!

On 300 west, and about 3400 south.  Someone here probably has the read address and phone number.

Adam

Here is a link you may find useful.

http://www.reefcentral.com/forums/showthread.php?s=&thre adid=169326&highlight=pin+method

Id get "Acrylite GP" (It MUST be GP if you go with Acrylite brand) from Regional Supply and have them cut it for you. The cutting charge is cheap ($10-15) and they cut to within 1/16". Then you need to find someone with a good jointer or router table to smooth the edges of the acrylic. Then use the "pin method" to connect the pieces (search "pin method" on reef central for more info). Use Weld-on 4 for joints (this is the "glue"). You will need an applicator bottle to apply it.  If you get lots of bubbles in the joints, run a bead of weld-on 16 along the edges. There may even be some members that have weld-on you can use.