After a couple hours of working on the stand I decided to start on my sump. I have been anxious to start this part of the project since I decided to build my own last week. I purchased a full 4x8 sheet of 1/4" cast acrylic (cast is supposed to be better for cutting than is extruded acrylic). I was a little nervous about cutting the acrylic as I have read more than one guy talk about how difficult it can be.
I bought a 60 tooth 10" blade for my table saw (the 80 tooth I wanted was to expensive). I also have a chop saw with a 60 tooth blade. I found cutting the acrylic to be really easy and not near as difficult as I had anticipated. I did not use any water spray or anything like that (a couple guys had recommended doing that to prevent melting). I found that the table saw was the easiest way to get good square cuts. I did use my chop saw as well.
The only difficult part was making the very first cut - my little table saw is not really set up for cutting full sheets.
After the first cut was made it was easier. I had to create a makeshift fence.
Slow and steady worked great.. no melting, no chipping....
After I had most of the pieces cut I decided to try the teeth for the overflow from the refugium. This also went smoothly and was no problem... I used a dovetail template which worked great. I hope the glueing goes as smoothly but I am guessing that is the hardest part...
After that I decided to tape it all together and see how it looked.
I would appreciate some advice here. The Melevsreef website does not list how tall the interior panels are so I am just guessing. The sump walls are 16" high, the Refugium walls are 14.5" high. The baffle between the first chamber and the second (flow is right to left) is 11". The first bubble trap baffle is 10" high. The second is 1.5" off the bottom and has a height of 11.5" and the third is 10" like the first. See any problems here?
I am also starting to think about my plumbing... I can supply water to the refugium from the skimmer or add a pipe with a valve and feed the refugium with water directly from the tank... Thoughts?