We used acrylic. Its cut so it fits fairly tight. I would never try to make an all acrylic tank with silicone, as Ive read it doesnt bond well to acrylic. For this use it worked just fine. Notice we siliconed along both sides of the baffles.. so even if for some reason the bond failed on the plexy.. the silicone bead on the glass would still hold the baffle in place. You have to get pretty creative siliconing the center baffle on the bubble trap. We used a long chop-stick to get the silicone down in there.
The plexi was about 40$. That was for the 4 pieces cut to the correct size. We made the "teeth" on the refugium baffle. This was a PITA. Im sure it would spill over just fine without the teeth.
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