Tony- THe herbie method is amazing, and even better, amazingly simple! Maybe I'll snap some pics of my 300 set up tonight to show how easy it really is. I'm not kidding when I say I can't hear it!
The trick with the herbie is getting a full syphon. On any normal durso, you have air and water falling down the stand pipes, where herbie, you only have water. It's unbelievable how much space air uses.
It's cost effective as well. If you're looking to do it, pm or I can try to write up a simple step by step.
Diogenes- Good start on your work today! We'll get you through this no problem at all!
I had to patch an acrylic sump that I had dropped anad cracked. I went to Rick's Fish and Pets in Frederick, Md and bought WELD-ON #16 clear, medium bodied solvent cement. It was $17 ( I was in a pinch and I'm sure theres something else out there cheaper that works just as good). This patched my sump up just fine.
For your return (from the pump outlet to the tank), I would just getsome clear .75" hose from Lowes or Home Depot. Your non-kink flex pipe will work for your return. Just make sure to get hose clamps for both so the hoses won't slide off.
Keep everyone updated. I've found over time that my favorite part of the hobby is setting up tanks and the DIY aspect of it. Possibilties are endless and everyone has a little different way of doing things. You'll realize how simple everything is once you do this for the first time, and then you'll wonder why you didnt do sumps a long time ago!