Ah yes such a good point. If I got glass baffles cut at a shop should I order them to exact dimensions or slightly shorter on the width?
For glass baffles:
— 3/16” (4.5mm) minimum glass thickness, 1/4” (6mm-6.5mm) preferred!
— leave any glass edges being siliconed sharp/square for maximum silicone contact area, request a dresses/smoothed edges on the top of each baffle, and the bottom of the “down” baffles! — glass is razor sharp if you leave a cut square edge untouched!
— I like to cut my baffles 3/16” narrower than the tank’s inside width, this gives 3/32” of air gap between baffle edge and tank wall on each side, just enough to inject silicone into! (1/8” narrower made the 1/16” gap at each end too darn small to comfortably inject silicone into! It's possible, but messy!)
— for “dam” baffles (aka “up baffles”) I like to mask with tape around 3/8” away from the glass on both sides to pull for clean silicone lines, this also provides a guide to lay the first bead of silicone on the bottom pane of the tank…
— lay the first bead of silicone on the bottom pane of the tank, place baffle down on it, align side-to side, square up/tape in place to top of tank, then inject silicone into both vertical seams!
— wipe silicone beads to a clean fillet, then pull masking tape before silicone skins over!
— after the “up” baffle(s) are cured for a day at least; you can begin on “down” baffles!
for “down baffles”:
— you’re only siliconing the two vertical seams; I like to use any random material like a chunks of lumber as spacers, 1”-1.5” thick…
— lay one spacer on the tank bottom, another vertically against the already siliconed “up” baffle…
— place your glass “down” baffle in place against the spacers, tape in place to “up” baffle, align side to side…
— inject silicone along both vertical seams, wipe fillet, pull masking tape (if applicable)! — (No need to square this one, as your first baffle is already square, so you can just press this one against the spacer between the two baffles!)
— cure silicone for 7 days in a relatively temp/humidity controlled environment, then enjoy your sump!