OK, on the sump....you can use just plain old window pane (4mm, I believe) for the baffles. I use 2 sets of 2 baffles in my 33g sump. You can find lots of pics on the net on where to put them. If you can't find anything, I can draw a picture. You can get the glass cut at any glass shop to the width of your sump (minus a few mil) and about 60% of the height (roughly)
I use a MAG 12 as a return to my 75g, which drains with a single 1.25" overflow. It feeds back to the tank via a 1" hose into a sea swirl.
For a skimmer I use a Euroreef ES5-2, rated for 90g. Really great skimmer and virtually silent. One was for sale here recently for $300, comes with pump.
For lighting, 2 x 250 will be fine for anything you'd want to keep. Do you have a canopy now? Essentially reflectors and socket assemblies are screwed into the inside of a wooden canopy, so you'll need the canopy first. It's pretty cheap to add retrofit reflectors into a canopy, relatively speaking.
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Brad
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