[I did it, I got rid of my bio balls and had the new space for an in sump Refugium,
Go to Home Depot, They sell acrylic in sheets, Don't go to thick
You cut the stuff by scoring the cut with a strong knife. I used one of those curved carpet cutting knives.
After you score it you put it in a vice and CRACK IT !!!
Its cool, You should have a nice straight cleaved edge
Use 2X4s the length of the Score as jaws in you vice.
Cut the first piece long enough to go down from the top of one side curve around the bottom, along the bottom and up to the top of the other side. I padded extra 1½ inches to the height of the down flow side of the refug.. This is so the down flow end is slightly higher and has a 1 inch lip. This lip is to keep the macro in the refuge.
Now the fun part. Pull out your hand Propane torch. Go out side. Figure out where your bends should be. One for the lip, two bends at the bottom. Mark the bends with a Marks o Lot.
Start heating the acrylic. Make fairly fast passes along the line. The Marks o Lot will disappear quickly with the heat. Continue heating till it starts going soft. Then make your bend. try to keep it squared up while your making your bends.
You should end up with a front, back, bottom and lip.
Next measure your sides two custom fit your creation. Then cut them from the remaining acrylic.
Fuse the sides to body with PS Weld On, #4 Acrylic cement.
Also sold at Home Depot. Spread it on both sides to be welded. Its the constancy of water. I used a Q-Tip. Wait about 5 to 10 seconds Then press the sides together. Hold it in place for a minute, while it sets up. Go back and bead the cement along the seam. The cement will be drawn into the Weld.
Pull out the Dreaml tool, attach a cone shaped stone and Drill/Melt a bunch of holes in the front of the refug. Cut/Drill/Melt some over flow slots on the top front of the refuge.
Drop it in the sump, hang a light over it and you done.
Get with me when its done and I'll give you a hand full of bubble and spear macro.
Good luck.
PS. I never Touched acrylic before I did this project. Since I have made a tool cady, a custom tank drain holder for the sump and a hood for the refug.]