Help new tank - DIY Fuge

[lv-reefer]

I just bought a new tank, it's 4x2x2, says it's 140 gallons. I had the tank plumbed with an overflow, now I need a fuge below.
This is my first set up with a fuge/sump. I plan to buy a Kent nautalis skimmer to put in it.
I want to have a kalk drip system set up below to replinish evaporation and help with calcium. I will probably use a 5 - 10 gallon container for this and the rest of the room I want to put a fuge.
I'm guessing I'll probably have 30x18 inches underneath for the fuge.
What will be the least expensive way for a fuge??? What size tank should I buy for the fuge? Also in making the baffles, can I just goto home depot and have them cut the acrylic/glass sheets and I can use silicon to glue them in??? How much space should I make the skimmer side and how much space should I make the return pump side??
I have read numerous posts and have many ideas on the design, but no one really has posted how much space you should require for the skimmer/return pump compartments.
Thanks for any help.

 

[krowleey]

I just made a sump myself with a 20L and home depot wont have acrylic it will be plexy glass and yes you can silicone it in. Just make sure you get aquarium silicone. i would sugest 1/4 it's nice and sturdy. good luck it's alot of fun

 

[mojosreef]

A 2 X 2 X 4 is a 120g. I would get a 30g long tank and make a sump out of it. I have made several sumps out of 30g, 29g, 20, and 10g tanks. The bigger you can use the better. Silicone will hold the plates in place just fine as long as it is 100% and does not say mildew resistant and its clear. I have used this without any problems. You can even get it caulking gun sizes.
Here is a digram of a sump I designed and has been made several times and works well. Good luck.

 

[mojosreef]

I agree if you are making it out of acrylic only but if you are just putting baffels in a glass tank silicone will work fine.