I just finished my 10ga sump. Assuming your tank is 12" high, i got 3 pieces of glass( 1/4") cut 8.5 high and the width of the tank (mine was 10 1/8"). Then i had two pieces cut 8.5" x 5". Here is a diagram similar to what i have but the single baffle and the three baffles together have switched places. The 3 together are an inch apart with a gap of 1 inch off the bottom with the center baffle.
My question is.. whats the easiest way to build a sump/refugian and how much does it run?
not sure what you mean by how much does it run but mine runs 24/7.
Will i have to take my whole tank down to start up the sump?
If you use an overflow...no but if you plan on drilling your tank...yes.
I suggest checking out http://www.melevsreef.com/
as it will help answer some of your questions and may give you a design idea for your sump that works for you. HTH
65 gal reef
2 PC's 192W each , 20 gal sump/fuge
4 false clowns, 2 firefish, cardinal, midas blennie, toadstool, zoos, shrooms, trumpet coral, torch, pagoda, frogspawn, poylps, red open brain, devils hand, hermits, snails, 3 cleaner shrimp, coral banded and a emerald crab.