sump advice

[Thunderfan]

I am building my sump out of a 30g tank and have a coulpe questions.
First thing is that I guess my tape measure reading skills where off the day I measured for my baffles. I had my glass cut at 11 1/2" wide and the tank is 11 3/4". I am going to use aquarium silicone to put it together. Is that too big a gap to try and fill? I hate to buy the glass twice by also don't want problems. It would be 1/8th on each side which doesn't sound like much but, might be when trying to fill with silicone.
Second thing is the way I am planning to set it up is drain/simmer, bubble trap, return, refugium. Baffles between drain and return 10" tall and baffle between return and fuge 13" tall. Tank is 16" tall and my dt is a 75. Will tee off return pump and feed fuge. Does this seem like a good way to set it up?

 

[91Atrac]

My opinion I wouldn't put the two returns. To me it just seems odd to have a mid return and end return. Cut the middle out, push everything over and add a freshwater chamber for ATo. Otherwise it sounds fine.

 

[Thunderfan]

I probably wasn't clear. There is only one return. 3 sections drain, return, fuge. I will have a separate container for ato.

 

[91Atrac]

Gotcha. Hard to see for me. Give it a try. Experimenting is what advances the hobby

 

[heathd.hd]

I'm sure you will be fine sealing the gaps with silicone. Might wanna do 2 passes is all. So fill the gaps one day let cure. Next day or 2 days later go over it again. But either way u should be fine. Also the setup sounds fine. I would just tee off your drain line and have it go to both side of your sump. Add a ball valve on your refugium side so you can adjust flow into the two sections. Like this picture. Or something like that anyways.

 

[Thunderfan]

Thanks for the input. I am doing a bean animal drain and I think I would have problems if I teed my drain.