Whoa...throttle back, good friend
We're not crazy. I've cut and milled acrylic sheet before...just keep the protective sheeting on while you do it to keep it scratch free. Common woodworking tools (table saw w/ a thin, fine-tooth cross-cut or plywood blade, jigsaw, finish sanders for dressing the edges, etc.) work just fine.
I will agree with you that making high-strength acrylic seams (i.e., joining a pair of right-angle sheets for an aquarium) takes skill (that means lots, and lots of practice on scrap pieces) and patience to properly build that tank so as to avoid avoid catastrophic failure and a lot of water in your livingroom. The edges have to be smooth, the seams perfectly mated, and the seaming solvent applied perfectly. This is beyond the time and skill levels of most casual craftsmen.
You can easily make an overflow for your aquarium by building a little corner box out of acrylic sheet and silicone adhesive (i.e., the silicone is okay since this is not a high-strength application; otherwise, use dedicated acrylic joining/seaming solvents). Most people can't cut glass properly or safely at home, so acrylic in this limited application is the way to go.
Once I finish shooting the gelcoat on my boat, I'm going to use some spare acrylic sheet in my garage to build a divider for one of this boat's livewells (keep different live baits separated).
I agree that Lexan (it's a polycarbonate, not an acrylic ester polymer) is out of the question for a tank...I've cut and milled Lexan to build framed security glass for my house in the same way as acrylic sheet, but it's very pricey and has specific cleaning requirements to avoid surface degradation and crazing. Laminates of Lexan polycarbonate make terrific bullet-resistant glazing.
v/r, N-A