I'd use glass but if you are going to use acrylic, don't use polycarbonate, and rough the edges of the acrylic with sand paper. If you are bonding the acrylic to make a box I would use weld-on, it actually chemically bonds the acrylic together.
i have a nice glass 10 gal bonded with silicone to the side wall. it works well. not much water pressure. id use weld on also if u go silicone route.easy as pie to use.
I have cut my own glass for my sumps and used aquarium sealant from a fish store. It is very easy to do. If you have an old tank setting around it would only cost you the sealant. And a cheap tool from Lowes. You will have the tool for other projects also. I am working on my 4th sump now with the same tool.
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