Step-by-step
Step 1: Plan the chamber layoutSketch on paper: chamber 1 = skimmer (water from overflow), chamber 2 = refugium (chaeto + reverse-cycle light), chamber 3 = return pump. Measure tank width and divide into 3 sections.
Step 2: Cut acrylic bafflesYou need 3 baffles for the bubble trap (panels alternating up/down/up). Plus 2 dividers for chambers. Cut acrylic to tank-width (slight clearance, 1/8 inch each side) by appropriate height.
Step 3: Test fit bafflesDry-fit all baffles in tank without silicone. Mark precise placement on tank glass with painter's tape. Verify spacing of bubble-trap baffles (1-2 inches apart).
Step 4: Clean tank glass + bafflesWipe with isopropyl alcohol. Silicone won't bond to greasy or dirty glass. Remove all dust + handprints.
Step 5: Apply silicone to bafflesRun a thick bead along the bottom + side edges of each baffle. Press firmly into place against tape lines. Smooth excess silicone with wet finger.
Step 6: Cure 7 daysMandatory 7-day cure for aquarium silicone. NEVER fill before 7 days - silicone is still releasing acetic acid that kills livestock.
Step 7: Water test 48 hoursFill with plain RODI water. Check for leaks at baffle joints + tank seams. Run for 48 hours minimum before transferring saltwater + livestock.
Step 8: Plumb and test equipmentAdd return pump in chamber 3, test full flow. Add skimmer in chamber 1, verify water depth matches manufacturer spec. Add refugium light + chaeto.