IMHO there is a big difference between re-building and re-sealing a tank. Either procedure is a PITA. Simple in theory, but tedious, time-consuming and wearisome in practice. Done correctly, the result is completely trustworthy and permanent. Done incorrectly...it isn't. And here's the catch: every inch of the total linear length of all the seams must be equally perfect. One bad spot, one imperfectly cleaned area, and the whole thing is a waste of time.
If it's an actual rebuild...where the glass panels are separated and then re-assembled...the same holds true, but it is literally two or three times as much work.
It's not a secret; it's very simple. Every square inch of glass that is contact with silicone must be absolutely clean, dry, oil-free and pristine. There must be no trace of old silicone left in place, and that's where most re-sealing jobs fall flat. New silicone will not adhere to old, cured silicone, so the old stuff must all be removed. Miserable, tedious work. "Good enough"...is not good enough.
A fellow for whom I worked building tanks almost a half-century ago was a little OCD, and so he was well-suited for this sort of obsessive attention to detail. He was such an artist with silicone that he would lay out the pieces of spotless, pre-cleaned glass on the tabletop, complete with jigs he built himself, in a room that was kept as clean and sterile as an operating theater. He would lay out a bead of silicone so precisely that when the glass was assembled, the amount that squeezed out of the seam was perfect for a quick finger wipe to create the internal sealing bead.
We mere mortals usually lay out a small bead that becomes the structural joint between pieces of glass, and then immediately after that apply a small bead around the entire internal seam length that is immediately smoothed into the sealing bead. This all has to be done fast, before any of the silicone begins to skin over.
Keep in mind that the structural bead is usually sufficient all by itself to create a strong, permanent water tight seal. The extra sealing bead is just a safety feature, in case there might be some tiny blip in the structural bead which doesn't put the assembly at risk of coming apart, but which might allow a slow leak.
So, if you have an older tank that has developed a slow leak, it's rarely necessary to re-build it. Strip off all the old internal seam...every last molecule of it...but leave the structural bead strictly alone. Replacing the internal bead will solve all your problems.
Oh, and the "old tank" thing? There must be a limit, but it's way, way higher than most seem to think. I know of at least three all-glass tanks...one of which I built myself, and the other two while assisting The Guru, that are over 50 years old and still holding water beautifully. Part of the reason is that back then, tanks were not made out of the thinnest glass imaginable; we used thicker stuff, which vastly increases the surface area and therefore the strength of the structural bead. 6-foot tanks were built with no cross-braces, and functioned perfectly. But the main ingredient is simply relentless, obsessive, unwavering attention to detail, mostly in cleaning.
By the way, those older thick-glass tanks were also better suited with their thicker structural seams to very slight imperfections in the stand. When you have a tank that suddenly, inexplicably begins to leak, the reason is often a stand that is not completely flat. Leaning a wee bit one way or the other is not the kiss of death many think it is, but if the tank is not completely and evenly supported all the way around...if it, for example, teeters a bit corner to corner...the stresses this sets up can be a tank-destroyer. Thinner glass tanks are more susceptible to this, and the cheaper-is-faster-is-better mentality that creates those tanks also contributes to stands that can just barely support the weight of the complete set-up, and which may very well be imperfect on the top edge.
Again...they don't build 'em the way they used to...
