Honestly to much time are my hands so cost isn’t an issue. I wanna make rocks like the big company make them for my next build I’ve been looking at the pricing for someone to make a custom aqua scape and it’s around 2k but doesn’t seem like it’s gonna meet my needs.
Totally get wanting to make it custom, but note that a company is likely to not be molding them but rather breaking up pieces and gluing them and using rods and stuff. Not making with Portland cement (probably, but please correct me).
I'm guessing if your estimate is 2k you're in the 120 gallon range, give or take 25 gallons. my suggestion assuming 100 gallons == 100 pounds: 75 pounds from breakdown/garage sale at say ~3$/pound = $225. Bleach & dump in a brute (drexel's advice), this is relatively dead rock so feel free break apart & cement as desired to make your structures. This makes base structure, then get ~15 pounds of live rock from your favorite clean LFS at say $10/lb = 150 and another 10lb of good ocean farmed stuff like the Aussie rock from Tankstop for like $30/lb = 300. Attach this onto your base structure with superglue or whatever, boom, custom structure for total $600 = average $6/lb and you get a mix of good rock types. Boiling that down, get most of your rock cheap and put it together yourself like the company would do, then use savings to get good live rock.
It's messy and it weighs A LOT more by volume compared to natural reef rock.
To Discotu's point, cement is SUPER heavy so you will find volume-wise, unless you like extreme NSA, that you need more lb/gallon. and suddenly your tank is a lot heavier, more weight on bottom glass, etc. Some things you could try (haven't done in aquariums but have done in other cement projects):
* negative molds / voids (put in small balloons, ping pong balls, etc that you can remove later or don't care about (ping pong balls) to lighten it up
* Cement needs aggregate, so you can use lighter aggegates than sand. I like those little styrofoam ~2mm balls - imagine shredding hard styrofoam board. To not look super ugly and have escapees floating around your water looking like the pacific garbage patch, you would need to basically do a plaster coat on top.
edit: underscoring how long you'll need to cure it with vinegar / other weak acids to make it safe for organisms, then remember the extra weight of cement vs porous aragonite rock is a tank safety consideration