Sump Baffle Material?

[tinpusher]

Acrylic is what was used on the site where I found the plans. I also thought acrylic woud be easier to work with as I have never done anything with glass. I will call the local glass man today and get a quote. Would you cut the baffles exactly to width (ie snug) or leave a bit for silicone between the baffle and tank side? Is there any specific silicone that you recommend? Are all silicones toxic free?

Thanks Muck and Delphinus