This is a long post but it explains my thought process.
I built most of my sump today. I will get to that in a moment.
I made a decision. I will not skin the stand. I've realised that since this tank is going to sit in an unfinished basement and since I don't intend to finish the basement any time soon, I will just leave the stand as is. There is no point making a piece of furniture when I'll probably build something a little nicer once the basement really is finished. This also means I'm not going to paint the stand to protect it from water or humidity. It was very cheap to make this frame with 2x4s but next time, I will use a better quality wood. Anyway, this is all a conversion for a later date; on to the sump.
I am using a 20 gallon high tank with dimensions of 24x12x16". There isn't any room for much except the skimmer, return pump, heater(s), and maybe some kind of mechanical filtration. Unlike other sumps I've built, I wanted the area when water enters the tank to be separate from the protein skimmer intake. I wanted to eliminate as much gunk from getting into the sump as possible. So these were the compartments I needed and their sizes:
1) Intake (4")
2) Skimmer area (10")
3) Return area (6")
4) Bubble trap (1" per baffle)
I whipped up a drawing that looks kind of like this:
Each gap between baffles was 1" and the glass is 3/16". Doing all the math is comes to 24".
I only needed 8" for the skimmer area but there wasn't much I could do with an extra 2" so I just made the skimmer area the biggest for any other stuff I might put in there.
So, I measured the width of my sump and it was about 12-1/4". Then I measured the width of the glass panes (3/16"). I multiplied this by 2 and subtracted that from the total width. The result: 11-7/8". This was how long my baffles had to be. For the height I picked my old standard of 10". You should choose a baffle height that meets your skimmer's manufacturer's requirement so that your skimmer can dump its clean water into the next compartment without mixing but mine has a requirement that is lower than the return pump can handle and since I can't raise the skimmer (it will no longer fit under the stand) I just picked a nice height that will work well enough.
I hit up the local glass shop and had five panes of glass cut for me. It took them about ½ hour to do so I took off to Lowes to grab some stuff then came back to pick them up.
Then I cut a 2x4 to the following lengths: 6", 4", 1". These were for place holders.
I used the blocks as place holders so that I could maintain the correct spacing. While the pane was held in place, I used a marker to mark where the glass would be. I didn't do this on the bottom of the tank though and you will see why in the "œtaping" paragraph. I do not like to mark the inside of the tank because there is no way to remove it before siliconing the pane in and I don't want those marks to show on the sump for eternity.
To save some time, I decided to place the baffles at both ends of the tank simultaneously and meet in the middle, rather than placing a baffle, waiting, placing another, etc. until I reach the opposite end. My pics will explain it better if that didn't make sense.
For each baffle that needed to attach to the bottom of the sump, I cut a small piece of the silicone away so that it would sit flush.
Then I added painter's tape to either side of the marks (inside the sump) and eyeballed where they would be for the bottom of the sump.
Then I taped the pane of glass I was adding. I taped all around but I didn't need to tape the top of the pane.
That doesn't look so good, so I cleaned it up with a gem blade. Don't use a gem blade to slice this way on your display tank. You could scratch it. I did this on the sump because, well, who cares.
I then placed a bead of silicone between the tape.
I placed the pane of glass into this spot and used my space blocks to keep the spacing. I made sure it lined up properly with the marks I put on the outside of the tank. I used my finger to move spread the silicone. Once I got the pane in place and was satisfied, I waited about 5 minutes then carefully peeled away the tape to reveal nice clean lines. See? Purdy!
Of course I messed up a few times so it wasn't all so pretty in the end but I'm not showing you that.
I repeated that for the opposite end of the sump and this was the result of stage 1:
Then I let that sit for about an hour. As an FYI, I used a 1" block on the bottom of the sump to hold the raised baffle up other blocks to space the baffles apart.
Then I placed the next set of baffles, waited, then the last set. This was the end result:
What will happen next is I will drill a hole for a ½" bulkhead into the lower area of the intake. I'm just waiting on my glass holesaw from Hong Kong. I will add a ball valve and use this to drain off debris from the sump when it collects.
The intake area will also serve as my mechanical filter area by means of a sponge. My biggest pet peeve is the debris that collects in a sump. I'm convinced this has been a major source of nutrients in all my tanks and I want to eliminate it this time around.
The sump designing is still in progress so I might modify it more but that is all for now.