Algae Scrubber Build Basics Summary
The Slot Pipe, Screen, and Fasteners
If you're doing a pump fed scrubber, either top of tank or sump, try to match the size of the slot pipe and other PVC components to the recommendations from the pump manufacturer, and if in doubt, err on the side of larger pipe. Larger pipe puts less head pressure on the pump, which will increase the flow rate.
Cutting the Slot
The width of the slot should be approximately 1/8" wide, the same length as the screen which you are using (as exact as possible), and as straight as possible. Cutting a straight, even width slot is arguably the most difficult part of building a scrubber. It is also one of the most important steps. If the slot is crooked, the screen may not hang properly, and there may be areas where the flow is lighter and heavier. This can result in sections of weak growth.
However you go about this, you might need a few tries to get good at it. PVC is cheap, so practice on a small section so you get used to how this is done. It's going to take a little time and patience "“ don't rush it. Mark the slot, and cut carefully.
If you mess up, do it again. Once you solvent weld an end cap and a union to it, it is not as cheap to replace (but still relatively cheap).
Doing it right means using a power tool. Probably the most common tool for this use is a rotary tool, or a Dremel, using a cutoff wheel:
Very recently, someone reported great success by using an oscillating tool. So if you're looking for a reason to add another tool to the arsenal, here's your chance.
Another idea is to use a router. Since plastics are "˜grabby', and plunge routing plastic takes extra grip and control, extra precautions apply - so this is not for the inexperienced, but it makes very straight slots. This method requires building a guide jig for the router, and a clamping system to keep the PVC firmly in place.
Reportedly, the best way to cut a perfectly slot straight is by using a table saw. However, there really is no way to cut a slot in the middle of a section of pipe (or across the whole length of the pipe) without removing the anti-kickback device and lowering the pipe on to the spinning blade. You could also do it with a handheld circular saw, but like the router method, you would need a jig and clamp system, and you still are lowering a spinning blade onto the PVC (if you're cutting the slot in the middle and leaving the ends uncut). I have never tried this and I do not recommend this method because it sounds too dangerous.
However you decide to cut the slot in the pipe, remember to observe all necessary safety precautions. Either that, or have someone else do it for you.