Unfortunately, things like this are the risks associated with used equipment. Moot question but was the tank holding water when you purchased it or was it dry in the garage?
Deals on used equipment are a gamble, as you can see. In this case, the gamble hasn't paid the dividends you anticipated. IMO, the only thing to do is to start over.
If I am in your position, I'm going on Craig's List and looking for a used 90 gallon which has been tested for leaks. Purchasing the tank, I take it home, give it a thorough cleaning and place it on a temporary stand. Then, I'd rig a canister filter to it, drop in a heater and siphon off water from the 240 to the 90.
Move all inhabitants to the 90 gallon, place your light on the 90 gallon and make peace with the fact that this will be a temporary home for all concerned. Now you can focus on the 240 repair without too much concern for your inhabitants.
Completely siphon off the remaining water (I once used a plastic kiddie pool to hold my water during a repair) and empty the tank of all substrate and remaining live rock.
Now give the tank a thorough cleaning as a clean surface is important, regardless of the solution you choose.
I use glass tanks as they are easier to repair. I've separated Aqueon tanks in the past to replace broken glass panels, something you can't do with acrylic.
But as I understand it, acrylic tanks are not glued, but welded so clear aquarium grade silicon isn't the best solution... or is it?
I'm wondering... considering the amount of water in the tank, if all seams of the tank were sealed with a silicon bead, wouldn't the extreme pressure of water against the silicon help to make a good seal?
It's worth a try, so I think that I would go this route. After 24 hours allowing the silicon to cure, I'd fill the tank with water from a garden hose and let it sit for a few weeks. If you don't have any leaks, I'd say problem solved.