Mike... please review my edited post and NEW pic. (the one you posted just now is off. Follow the pic I posted for the way the water will flow. Water cannot go through a baffle the way you had it )
This setup, following what you wanted to accomplish, would be ideal IMO
. You would just have to purchase the last four baffles (or cut) to the same size, and the first piece slightly taller (the first baffle). If you notice, all of the other 2nd, 3rd, 4th and 5th baffles are the same size. The one in the middle of the bubble trap is just elevated (like in my sump plans). Just follow the pic, and you should be home free.
I would go with 1/4" plexi. If the sump is glass, then 5/16" would be sufficient. (1/4" if you can afford it... but not necessary). I used glass, and used pure silicon made for aquariums (at HD
). Glass won't stick to acrylic well at all though... so if you do use acrylic, make sure to use a lot of the silicon to keep things semi-secure. Remember... you will have to regularly reinforce this. BUT... If your sump is made of acrylic, then you're in luck!
Check with plastic stores around your area for acrylic glue (forget the # of glue that you use). That stuff bonds acrylic to acrylic like CRAZY. Good luck!!