Absolutely dude! The thing you're doing wrong is working with acrylic! Arrrggghhhh!! $$$$$$. No no no.
Here's THE cheap W/D kit:
Step one: Go to Home Depot/Wal Mart/Big store of your choice and buy a rubbermaid tub, the pipe necessary to do everything and three bricks. The tub is the sump, the pipe gets the water from your tank to the sump. The bricks are bricks. They come in handy in a few minutes. It's a good idea to let all manufactured things soak in fresh water for ~24 hours before incorporating into a ceph system.
Step Two. Go to
www.thatfishplace.com or
www.drfostersmith.com and order the following: a good pump (a mag drive pump or some such) the tubing to get the water back UP to your tank from aforementioned pump, and a 5 gallon bucket of bio balls.
Step three. Wait for all that stuff to arrive. In the meantime, you have to create a spillover for your main tank, to get tank water over the wall of the aquarium and into the plumbing that takes it to the sump. This is the trickiest part of the whole thing. You're really best off buying one. Look for one on Ebay, or ask the LFS if they got a used one in the back of the store somewhere. Also, go a dollar store and buy a plastic collander. PLASTIC. I mean it.
Step 4. the bio balls and pump arrived. Rip the lid off the 5 gallon bucket of bio balls, take out the free T shirt and whatever marketing propoganda is in there. Put the lid back on. Turn the bucket over and use a 3/4 inch drill bit to drill a couple dozen holes in the bottom of the bucket, and maybe a few around the bottom rim. Bingo, you have a bio tower! Take the lid back off (umm, turn the bucket right side up first.) and place the twoer on the three bricks in your sump. Remember, alway soak manufactrured things for 24 hours before running tank water through them. Take your collander and put it on top of the bio balls upside down, so the tank water from the plumbing spills onto it. The water will trickle through the holes into the bio balls, and the mag drive pump will return it to your tank.
Voila! A W/D system easily capable of sustaining 300 gallons of sealife, for about 50 bucks, not including that pump or the overspill.
Good luck! Jimbo