It will be tough without a skill saw. I made a 4'x2'x2' and a 4'x2'x1'6". For the 4'x2'x2' I used half inch plywood 1/2"x4'x2'(I need 5 sheets) and 1" or 1.5" wood screws every 6-8". Nail's will probably split the wood. I drilled pilot holes then screwed them in.
I put the bottom down screwed the back in then the top. After that I measured on the left side back to the front on the bottom, then back to the front on the top. Then on the Right side back to the front on the bottom, then back to the front on the top. They were off slightly so I had to cut the sides out a fraction of an inch.
Oh man this is sounding confusing...
Basically all my measurements were right in theory but in reality the wood is slightly smaller than what it's displayed as. I wish I took pictures on the build process.
I bought 5 of these. 1 bottom, 1 top, 1 back, 1 for the 2 sides cut in half minus 15/32" because it's of the back is 15/32"(2'x1'11
15/32" x 15/32"), 1 for the front two pieces 4" up and minus almost an inch left and right so it will fit inside (4"x3'11"x15/32").
http://www.lowes.com/pd_7706-99899-...rentURL=?Ns=p_product_avg_rating|1&facetInfo=
2 of these.
http://www.lowes.com/pd_11220-1638-...pl=1¤tURL=?Ntt=acrylic+sheet&facetInfo=
Couldn't find this on the website but it's an "Acrylic Cutting tool"
https://www.youtube.com/watch?v=jCeHx-vvJ7k
2 of these. To put the plexiglass in as mickey mouse glass tracks. I used the 1/4" ones I'm going to try the 1/2" next build.
http://www.lowes.com/pd_215769-3767...1¤tURL=?Ntt=aluminum+channel&facetInfo=
And an outdoor paint to seal it.
Here's a google sketch up of my measurements if this helps.
http://sketchup.google.com/3dwarehouse/details?mid=49f9040e103abd3cfe287e9b97e73eda
The top vivarium is 4'x2'x1'6" with lights on top of the vivarium, the bottom one is the 4'x2'x2' with the lights inside the vivarium.
Good luck! If you live close to me Long Beach, CA, send me a Private Message I can have one built in 1-2 days.