I finally got the sump filter built and installed on my 6' tank
It's made from a 3' tank I had spare to which I added three dividers and cut a hole in the end for the in-feed. Cutting the 35mm hole in the back of my 6' tank was nerve-wracking but worked out just fine in the end. I got the diamond hole cutter on Ebay for $20, cut the holes then sold it to someone else for $17 - a real bargain.
The first stage has a fine wool pad followed by a course sponge, activated carbon (not visible in the photo's) and finally Ceramic Noodles.
The second stage has bio balls, Japanese matting, cerami-sub and finished off with fine wool pads.
Stage 3 is currently empty and the fourth stage has the heater and return pump.
The return is by way of 15mm retic' pipe drilled to act as a spray bar.
The noodles and bio balls were from my original canister filters so that it would be pre-seeded which seemed to work out fine as well.
I had to modify the cabinet to be able to remove the middle door and its support so that I could get the sump in.
It was a bit of a logistics nightmare moving everything out of the tank setting it all up and then moving everything back in but the money I got selling my canister filters easily paid for the sump with money left over and the tank looks so much better with no pipes, heaters or anything else visible.
I now need to decide what to do with the spare stage - I have thought about putting a light in the cabinet and putting plants in this section to help remove Nitrates but I have no experience with this at the moment.