I used the BA on a 75g with a 29g sump. This is the fourth BA I've used, and would never go with anything else. I've always used 1" plumbing for the entire drain setup, never saw a reason to expand the size of the plumbing. For the open channel, you can really just drill a 3/16" hole in the cap, and stuff an airline hose in. Has worked great for me.
In terms of the sump baffles. I've always used acrylic, and I've always siliconed them in. Since they aren't holding a huge degree of pressure, they will be fine. I would never silicone acrylic to hold back a volume of water, but for water flowing over, it works great.
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