D-man,
make this into a build thread so we can see pics of it and help you out with any questions.
For the screen i went to jo-ann fabrics and got thier plastic mesh screen, they had two different sizes, one has small holes and one has bigger holes, ive seen both used with success.
I have the screen with the smaller holes.
The real key to the screen is getting it really roughed up. you want it to feel just like a cactus. To do this take a hole saw and scrpae it around on both sides of the screen for a long time until you get every inch of the screen really rough.
This is the most labor intesnive opart of the project by far. took me about 20 minutes or so per side. also do it on something you can clean off becasue you will have little piles of plastic all over when you are done. i did it on a piece of plywood in my living room while I watched TV
If you havn't done so allready be sure to check on what screen size is neccesary for your size tank and start there.