If you're worried about the seams reinforce them by siliconing some plastic, wood or aluminum corner covers on them.
A Herbie will not be quiet with a surge, especially 1 gallon on such a small tank. A Herbie works on the bases of steady state flow.
I'm just going to come out with this, seriously a surge on a 5.5?? What possible benefit could you get from that? Noise and air bubbles, sounds kind of silly to me when you could use a maxijet on a timer and get the same random flow without the complications. Call me crazy but I usually try and avoid things that are unnecessary and cause problems and complications, but maybe that's just me.
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