Awesome drilling job! 
 
Don't sweat it though, you're not the first one to break a tank. Just be glad you did it to an empty one
I forgot to square up a DIY stand once and cracked a 75 gal from top left corner to bottom right. It sounded like a shot gun going off in the fish room followed by a mini tsunami flooding the room. Everything except the tank and my ego survived…
 
 
But back to your new acrylic sump!
 
So is this one tank going to be the entire sump or are you still going for the double container sump idea?
 
I do not like the idea of baffles ever going all the way to the top. If something clogs or goofs up I want the water to be able to spill over the baffle without spilling out of the sump… at least until both sides of the baffle fills up…
 
If it’s practical to trim an inch or so off the baffle that goes all the way to the top then sure, do that… if not then just drill a few holes in it. Your handy with a drill aren’t ya (lol, sorry, I had to
)
 
I have to know if this is the only container… and if not what will the other container be… before I offer much. Chances are I’m going to recommend you keep what you have and add a couple of baffles though. If you have a big chunk of 1.5” coarse sponge then it makes sense to have two baffles 1.25~1.5” (depending on how coarse) apart allowing that sponge to be placed between baffles.
 
 
Seriously, sorry your drilling experience didn’t go so well. I’ve yet to put drill to glass myself and reading this makes it less likely I will any time soon. It looks like that acrylic sump will work well for you and be much easier to work with. I think it opened your options up pretty nicely.
 
Don't sweat it though, you're not the first one to break a tank. Just be glad you did it to an empty one
 
 
But back to your new acrylic sump!
 
So is this one tank going to be the entire sump or are you still going for the double container sump idea?
 
I do not like the idea of baffles ever going all the way to the top. If something clogs or goofs up I want the water to be able to spill over the baffle without spilling out of the sump… at least until both sides of the baffle fills up…
 
If it’s practical to trim an inch or so off the baffle that goes all the way to the top then sure, do that… if not then just drill a few holes in it. Your handy with a drill aren’t ya (lol, sorry, I had to
 
I have to know if this is the only container… and if not what will the other container be… before I offer much. Chances are I’m going to recommend you keep what you have and add a couple of baffles though. If you have a big chunk of 1.5” coarse sponge then it makes sense to have two baffles 1.25~1.5” (depending on how coarse) apart allowing that sponge to be placed between baffles.
 
 
Seriously, sorry your drilling experience didn’t go so well. I’ve yet to put drill to glass myself and reading this makes it less likely I will any time soon. It looks like that acrylic sump will work well for you and be much easier to work with. I think it opened your options up pretty nicely.

that is why i went and got acrylic.The reason i have to drill is i only have 24 inches of hight under the stand.So i can't raise the tote and have access too it like in your design.I have drilled the tote 4 inches down from the top with a 2 and a half inch bulk head.If you think that will not work let me know.I was so pist i had to laugh!!!!!I gotto tell ya i would




