Jeff S
I'm not sure how you would go about making baffles in a Rubbermaid container. I've toy'd around with this idea myself, and have yet to come up with a "good" way to do it.
Having a "rigid" Rubbermaid type container will certainly help - but the less rigid ones do "flex" upon filling with water, and I see this as a problem with gluing in traditional baffles.
I had to go with a separate refugium and sump, both made from Rubbermaid containers, not by choice, but by necessesity. I wanted everything under the tank out of site, and this was my only option for the size/capacity I was shooting for.
18 gallon refugium with 14 gallon sump, and I run my refugium almost full to the top - almost.
Any glass tank other than a 10 gallon will not fit under most stands unless placed under the stand BEFORE filling your display tank. Then of course you run the risk of having a problem with the glass sump someday, like it developing a slow leak, and not being able to remove it from underneath. Unless you tear down the main tank, to get the glass sump tank out, you're in deep trouble.
But .........
If you have the room - as many do with larger tanks/stands - then JohnnySalt has hit the nail on the head - a glass tank gives one many more options on DIY sumps - especially in regards to baffles.
For us "less fortunate" ones with limited space though, Rubbermaid or something similar may be the next best route to go.
If you are planning on setting up the sump somewhere other than under the tank - well then the sky's the limit. Huge sump/refugium piped back to your display tank to me would be ideal.
If I think of anything, or try something on my pseudo sump, I'll make sure to let you know.
Meanwhile ... maybe some others here have done this, or have some suggestions <img src="graemlins//confused.gif" border="0" alt="[confused]" />