I decided to be brave and have a go at custom building a sump out of some perspex I had kicking around at work. I'ts a very interesting material to work with. I prefer glass, but getting some perspex skills under your belt allows you to quickly build handy things like sump stands, racks, holders etc.
I cut the pieces to size with a skill-saw. I used a plywood blade and pulled the blade up so it just went through the sheet. This kept the cuts nice and clean. I clamp a spirit level to the table and run the saw down the side of it for a clean straight cut.
I taped it and then applied methylene chloride with a needle squeeze bottle to the edges. At this point it became apparent how important a clean cut was to create a strong bond.
I added some corner braces to add a bit of strength, and then slapped in the baffles. I was working with the bare minimum of space, and had to opt for a U flow sump design so I could cram the Euro-reef skimmer in there, and still have room for an area I could grow chaeto and add a filter sock. In the end I managed to successfully fit it all in.
In the next build, a big sump area is a must. I'd really like to cram a fluidized reactor in there to run GFO, but I would have to sacrifice the fuge area. I'm going to see how I go, but may rearrange this setup.