Sump, baffels plastic or glass? and how tall?

What is your sump constructed out of. Glass or acrylic? There is a really good thread in the newbie section on this subject that has just started. Check it out.

I'd use glass- less chance of the silicone giving way.

The height is individual- and determines how full your sump stays during normal operation. You want this "normal" capacity to leave enough room for all the overflow water that will come down in the event of a power outage. Spend whatever time necessary to get this right, and test it several times during your tapwater test. Sooner or later you will lose power- you have to leave enough room to handle it, or a flood is guaranteed.
Also- certain skimmers have recommended depths of operation, so this would influence your baffle height as well.

I would leave out the bioballs and put the return pump in a chamber separate from the skimmer so micro bubbles are less of a factor.
There are many suggested styles and other helpful info
http://www.melevsreef.com/what_sump.html - I couldn't have done it without this page!!

That's mainly used 'after' the chamber containing the protein skimmer. It's main purpose is to get rid of those little bubbles output by the skimmer.

You might want to put the skimmer before the fuge on the intake side.It will help with settlement on your macro and sandbed.

I used a 30 gallon for my sump/fuge..... used 1/4" acrylic for the baffles..... I have about a 13" section for the overflow and skimmer..... then about 17" for the fuge........ then about 6" for the pump/return section...... with a small bubble trap between the fuge and the return to help make sure I get no microbubbles..... I agree with plantman....... you do not want the skimmer in the same area as the return...... you'll end up with microbubble problems..... I also feel you should not use bioballs..... they are just a nitrate trap. And........ look at melevsreef....... invaluable info on sumps....

JMO

Dan