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I made a sump out of a 20 gallon long. I called a local glass shop and they cut the baffels for me to size out of glass for about 12 bucks while I waited.
I tried acrylic first, but it bowed and flexed under the water pressure too much.
Give a glass shop a call and see what you can get.
you have to be careful with the silicone, silicone II have a quimical to prevent mold, and algae, so thats not good, i think the silicone I is the one that is pure silicone, just read the back of the bottle
Hey Jazz, quite frankly, I didn't want to take the chance with silicone. Lowes has a tube of silicone that specifically says "Aquarium Silicone" on it for around $3.00. When you are talking about pennies in price difference, why take the chance? That's what I used.
Oh, and when you call the glass house, ask them if they can round or "polish" the edges for you. Some will, some won't, some will charge. It will make the flow over the baffles that much easier. My glass house did it for no extra charge. (of course, I struck up conversation first and the old guy that runs the place was facinated about the project I was using the glass for! Sometimes that helps too! LOL! )
Wow, I am really glad that I asked these questions. I have been learning a lot. This is the first "glass" project I have worked on and I am worried about screwing up.