I have not done this so I am not speaking from experience but from the research I have done. Many people have told me that even if sealed with quickcrete, polyurathane sealant, and/or epoxy a pleco will eventually eat through it and reveal the foam. I guess plecos' mouths are much stronger than I thought. I can't wait to see your finished product. I have been wanting to do it but I also want plecos so I will have to choose between one or the other...plus, a DIY background on 500 gallons will be a massive undertaking.