I did one for my old 90. Made a big overflow cover. It is currently in my 270. Some of the epoxy/sand/crushed coral mixture got busted up when I switched tanks, but otherwise I think it looks good.
If I did it again I would use more epoxy, use the epoxy they talk about in some of the threads (I used fiberglass resin), and I would probably go with the black pond foam. It is supposed to be denser, more durable, and is fish safe according to the company. You'd just have to use more sand/epoxy to get it covered and looking nicer. Of course, you could probably even put some of the sand right into the foam as you're applying it.
My one word of advice is that you better make sure you have a way of securing it in your tank. I used really dense rock and only filled foam in between them and the thing still tried to float (has to weigh close to 30 lbs out of the water).