If your handy go get the plastic trim that is used for screen windows there are clips for the corners to join. That the mesh and the rubber stopper that hold screen in and your flying

Good idea, will have to check it out. I don't like the eggcrate at all, but for now it works. I added a wrasse who jumps at the surface every time I feed, I'm sure he would have ended up on the carpet the first day he went in. I've had enough fish jump that a cover is a must.

Mrhasan, your tank looks awesome btw!

I did check out lexan polycabonate sheet but they are just too expensive. I heard that no fishes are small enough to go through 1/4" mesh :P

Yap I am, for now, inclined towards going the mesh cover way. Still thinking.......

Thank you :D

Made my top from window screen frame and "Select Plastic Chicken Wire" from Home Hardware. It comes in 24", 36" or 48" x 50 ft rolls for around $20. It is made by Quest Plastics. 1/4 squares and it is greyish clear.

I think I got the same thing as Smudge. Here's a pick:
http://i1177.photobucket.com/albums/...psf53da302.jpg

It's a bit bigger than 1/4", closer to 3/8" but I've not had anything make it through, but the operative word might be "yet" :)
http://i1177.photobucket.com/albums/...ps130f97e8.jpg

http://i1177.photobucket.com/albums/...ps29e029ba.jpg

I went to Home Depot, in their screen door section you can get the rails, corners etc to make the frame.
When I made the one for my 77, I made little "U" shape cutouts to go around my returns which are over the rim. Don't do it, it sucked, looked horrible and really made the back of the frame weak so it tended to sag. I even used corners and little cut rails to go around everything.
If I were you, I'd make it as wide as I could from front to whatever sticks out the most in the back. That will leave a bit exposed probably between the frame and the actual rim at the back.

I also tried egg crate, but I found it probably reduced the light in my tank 20-30% (rough guess).

Hope that helps :)

Yes thats the same stuff I am using. I have had a fire fish jump through. :(

Rai PM me your addy and how much you need and when I get back home I'll send you a chunk

Thank you so much for the pictures. Will help me a lot in case I can't explain it to home depot :P

So I have decided to make a square screen and fill up the small gaps between the filter, skimmer and float switch with egg crate pieces since its going to be a PITA to fill the spaces with the screen.

I glued the eggcrate to the back of the aluminum frame with hot glue. A couple pieces have come loose and I have reattached with super glue. Seem to be holding up.

Awesome. That's what I plan to do too. Thanks for the heads up :)