Just remember that the baffles dont have to be sealed around the edges. What you are trying to do is slow down the flow of water enough to allow the bubbles to rise and burst.. I have had great success using plexiglass in my rubbermaid.
Here's an effective way to baffle around your return pump. The idea is to make two (or more) baffle enclousures into which you sit your return pump.
1. determine the average depth of water in your sump. cut a strip of plexiglass as wide as that measurement. This strip needs to be long enough so you can bend it into a square (or a circle, doesnt matter which) which will provide enough room to set your pump iinto. Also, make it large enough so you can place the next baffle you're going to make inside of it.
2. Now make another strip . Cut it about 1/2" narrower than the water height measurement. Bend this strip so that it fits inside the first one leaving about 1" of space all around it.
3. Find some PVC or large flexible tubing and cut 4 or 6 1" long pieces. These will be used as legs for the larger plexi box. Notch them with a hack saw and fix them to the bottom of the first plexiglass box u made. They need to elevate the piece at least 1/2"
Ok, so the idea is that the first baffle makes the water flow under it, and the second baffle, which has no legs and sits on the bottom makes the water flow over it.
There is no need to seal the ends of this baffle so it's a solid box, just bend it so they meet fairly closely.
Hopefully this drawing will explain it better.
The view on the left of this pic is top view looking down, showing the two plexiglass strips bent into a box. The right side of the pic illustrates a cut away side view, showing the outter box being elevated, the inner flush on the bottom.
"A BRW Original"
