Good information, thanks for taking the time to do this write up. I have been considering building an acrylic tank for a while and every bit of info helps.
To be fair cars made now are made way better than they they were in the '50's . From safety, gas mileage, maintenance, all the way to reliably and dependability. I know because i have a '56 Cadillac.Sorry to hear that cool keith...i just dont know why this glue kinda "disapeared" for so many years as it was used to make all my 20yr old plus tanks so i feel the traditions should have been carried through. People are cheap these days and dont care about quality products like they used too. Kinda like new cars compared to ones made in the 50's i guess lol.
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Sounds like u have the right idea for #4 (aestetics) and #40 (final seal)...center overflow can be cut out and sealed with a piece of acrylic and #40 also. I usually use the thickness of the tank bottom as a rule of thumb but any thickness 1/4"-1" will work. As for cutting the overflow box out i usually use a dremel with the small extension tool for engraving equiped with a "rotozip" bit. Cuts through like butter . If you dont have a dremel and rotozip bit a fine tooth blade from a hack saw will work but it takes a long time by hand. Dont try and "knock" it out it will just crack the floor of the tank and still be attached. Acrylic joints can only be removed by cutting with a skillsaw,dremel/rotozip bit or some kind of fine tooth hand saw blade. If you are really patient and only have a drill you could also just drill holes all the way around the box until its cut but its not the prettiest.OK thanks. I appreciate it. I was thinking of using the #4 more for aesthetics. I am hoping it will fill in some so i dont see the crazing so much since the tank wont be hidden in a wall. Also was wondering if I can delete the center overflow by knocking it out and covering the hole with a 1" piece of acrylic. Thanks again