Can't Find Properly Sized Sump Tank
I recently decided to redo the sump system on my 55gal tank in order to make a few improvements. One of the goals is to replace the sump tank, an old glass 10 gallon aquarium, with a plastic tank that is longer, less fragile, and easy to drill for a bulkhead mounted float valve. A standard 10 gallon aquarium is actually a little too wide (front to back) to fit completely inside my stand. The only reason it works is that it is short enough (side to side) to sit in the doorway of the stand. The doors mount to the outside of the vertical braces, so they are just barely able to close with the aquarium sitting in the middle of the stand.
I need a tank about 12" deep to allow enough travel in the float and still keep the sponge filter covered in water. Because I'm not using an overflow box in the main aquarium, the water level in the sump tank fluxuates depending upon the flow rate, and is regulated by a float valve. So, what I need is a plastic tank that is 12" deep, no more than 10" wide (including any rim), and 24-30 inches long.
I've looked at all sorts of plastic tanks and containers every place I can think of, and can't find what I'm looking for. Everything I've found with enough depth and length is 12" wide or more. I really didn't want to mess with making a custom tank, but if the local glass shop can cut acrylic sheets to the sizes I want for a reasonable cost I may end up going that route. I just hate to pay $40 for acrylic and mess with silicone when there are hundreds of polypropylene and polyethylene tanks and storage containers for around $10-$15. Does anybody have any ideas on where I can find a tank/container the size I'm looking for? It seems like there has to be one somewhere.
Right now I've got a pair of cheap plastic containers that are 11" deep, 9" wide, and 12" long plus the "handles" on the edge. I drilled them to accept some bulkhead fittings I got second hand for free so I can plumb them together. They will probably work as a temporary solution, but there is very little room for the pump and filter and my submersible heater won't fit inside them; which means I've got to find a better solution before fall.
Any suggestions would be appreciated.