Thanks Landon. The acrylic is really easy to work with. I used Weld-On #3 and it dries in about 30 seconds.
I must have missed that about the baffles. If you look at Melev's site he only has an over/under/over. It wouldn't be hard to add one more baffle. The acrlic is so easy to glue I could do it right in the sump.
Do you think the area in the refugium or return is too small?