As promised: Sump build.
The sump is 90% complete have to add the baffles. The build went well. No problems. I have included a lot of photos because some N-R.com members are curious what it takes to build their own custom sump.
Here is the sump. Just try to imagine it. Then you can see it.

Look at that 1 inch to spare on the sides. I did good on planning the sump out of 2 36x30 sheets of acrylic.

Triple checked my measurements. I stuck with my tape measure for consistency.

1st cut went smoothly. Just slow and steady for a nice clean cut.

What to expect while cutting acrylic. Tiny pieces that are static charged and stick to everything. Remember to thoroughly clean both the acrylic and table saw (hence the big fluffy bristle brush) and blade after each cut to minimize the scratching that can occur if a piece of "dust" gets under the acrylic while pushing it against the table saw. And yes that is an old box of crap holding it up. Another ebay item.

To help with creating a clean and consistent bond with the acrylic I recommend wet sanding the edges that are to be glued with a sanding block. This is my very cheap solution. That is 120 grit sand paper.

Here is the solvent and patch solvent. After building the sump leak test it and any spots use the #16.

Using long enough clamps, clamp it. You do not want excessive force or you will bend the acrylic out of place. I used 2 90* devices. A speed square and a 18'' square. They where what I had handy. The 2x4 was used to push the center into place because I could not reach it with my hands.

Perfect fit. Measure twice cut once.

This is how you apply the solvent weld-on #4. A small brush that comes to a point is ideal I had a 1 incher so I used it. The solvent "sucks" under the joint. You can visually see where it is because the joint appears "wet"

Try not to overdose the joints. This is what will happen when too much is applied and it soaks through to the other side and under. Fortunately this is a sump and its on the bottom. I do not care about the look.

2 36'' sides done now for the 10.625'' sides to be installed. Monster can for size reference.

Last side sitting for 2 hours waiting for the bond to be strong enough

Pretty clean bond. The less bubbles you see the better. Ideally you will want zero, to achieve that a lot of time consuming sanding is needed with much higher grit. It's a sump. I don't care.

Woot its almost DONE!!! just cut 2, maybe 3 baffles and drop them in. They add support for bowing also.

Sorry for such a long post. Hope this helps people. Don't forget to test for leaks. #16 should fill the leak. I like to coat all exterior joints with silicone also. It's an extra piece of mind for me.
Tomorrow Home Depot run for pvc piping for the overflow, return and spray bar. Also purchase some smaller sheet for baffles, and a top brace for the sump.