Well, I order them pre made cuz I find routing teeth to be one of the biggest PITAs around. I get them made from firstclassaquatics.com, barraquatics, and right now I am having Myreefcreations make a few. You use 1/4"-3/8" black cast acrylic...tell them where to cut the teeth, pay them $30-40 or whatever, and when you get it in the mail...use silicone to glue it in. Now, technically, silicone wont hold plastic like it does glass...but in this case...the pressure on both sides will be rather close (the water in the sump section will be what...2-3" below the other side?) and the plastic wont go anywhere.
I dont have themdrill the holes for piping and bulkheads however. I wait until I get it, then plan out my plumbing, and drill the holes myself with a hole saw...on acrylic its simple enough.