How to make a DIY Overflow Box. Here is our guide to making this amazing mini overflow box with parts from in town! This is a MINI overflow box that was made with sheets of acrylic from menards and acrylic cement from tap plastics. How to score acrylic sheets.
What you will need: Cutting blade (for scoring acrylic sheets), Acrylic Cement #4 or #16, electrical tape, sandpaper (varieties between 60 and 220 grit), "bent tube" 90 degree bent tube about 1" dia. (old filter tube will work). sharp xacto blade or retractable blade, ruler, angle measuring tool (protractor), clamps, hacksaw, 1 5/8" hole saw bit, All Connectors shown,(2)  1 5/8" rubber gaskets,
Here are some options for making your DIY overflow box, for building this box we use the two middle piece's and the top right piece shown below only.
Hacksaw for cutting a connecting piece in half, one will be used to secure the overflow tube to the sump, the other is leftover. O rings for water tight seal.
If you don't have acrylic sheet bending equipment here is a cheap way to "BEND" a piece for your overflow box!
Heat an Iron and flip it upside down and secure it. This will be the "HOT" table. Hold the piece over it for about 30 seconds then flip it over and do the same for the other side. Once the material is soft you can take a piece of wood and curve it around the block to get a smooth edge.
Use an old scrap piece to see how the iron will bend the piece if used right.
Tube is cut and an extension added to the other side, making a symmetrical "U" Shaped tube.
(clamps and wood blocks are recommended but not absolutely necessary to Break or Score acrylic sheets. This method is very accurate to make small acrylic sheets to make a DIY overflow box ect.)
Acrylic Cement and Applicator Bottles (needle tip or accurate application, you can use a syringe or equivelent)
What some acrylic sheets and cement can make..
To smooth edge's you can "rig" up something like this, use a utility knife blade and make sure it's at 90 degrees. Then you can "SCRAPE" the edge's flat quickly.
Here is how to break the sheets to size, Clamp down after scoring both sides and bend the sheet and it will break right on your blade mark.
Find a size to make the sheets.
Scoring Acrylic Sheets
Ruler and Cutting blade will "score" the material making it possible to break along a perfect line. Score both side's as accurately as possible then break, sand then scrape edge's before cementing into an overflow box.
It's easier with clamps and wood strips to hold the acrylic shown below, after scoring with a blade on both sides, bend it hard and quick to cut piece's to size.  Use this scoring and "sanding/scraping" method to make 2 overflow boxes. Then bend a piece and cement the boxes together as shown, drill for the connectors before making the box.
Breaking Acrylic Sheets
  Breaking the sheets can be done by hand if necessary.
Use an angle measuring tool to make sure you have a 90 degree angle on your blade secured with clamps and wood strips.
Lay a piece of 200-300 grit sandpaper on a flat surface (such as a table) lightly sand the edge's flat holding the piece at 90 degrees, then scrape for rough surfaces. Don't round the edge's or it will not cement well. Use the scraping method and sanding together for a perfect edge for cementing acrylic sheets.
Carefully scrape pulling up to get a smooth edge, use sandpaper on a flat surface and this method to get edge's smooth to bond with cement.
Here is an assortment of hardware store bought connecting parts perfect for a simple overflow box. Use the best way for a water-tight seal with rubber gaskets and the correct size hole cut in the acrylic for a leak free box.
Perfect lower sump connector that will fit underneath an aquarium stand. With leftover piece's make another box!
Overflow Box Drain, use a dremel or hole saw and cut the hole very accurately for leak free seal, or drill before cutting the sheets and building the box with a wood boring bit and plug-in drill. Flat blade wood boring bits will drill acrylic sheets if you use a wood block underneath the acrylic and keep blade at a medium to high speed to "melt" the acrylic and make a perfect hole.
Drilling hole for drain Tube
Use plexi-glass or acrylic cutting blades for jigsaw cuts, or pointed tip wood boring bit for drilling.
Hole saw bits are the best for acrylic drilling, it will heat up the material making an accurate cut that will need to be trimmed for melted acrylic around the cut.
It might be possible for this setup but used is the larger female connector instead of the male connector shown below.
Sump tank DIY Setup. A piece of tubing connector found at a local hardware store, while your there get the exact size wood boring bit to cut the acrylic, it needs to be the flat head design (NO "screw head designs").
Overflow Box Parts Search
 Drill for drain attachments. Used is a 1 5/8" hole saw, it will fit the connectors shown.
The hole after drilling, flake the excess acrylic off while its still hot and it's easier.
Nice thing about the underground sprinkler connectors is they are all 1 5/8" total openings. Use a 1 5/8" hole saw bit. Available at local hardware stores!
Cut off part of a two sided connector as shown (available at hardware store). The smaller piece allows a smaller nut to secure the connector to the top of a sump filter. See SUMP PAGE for instructions on a DIY SUMP Refugium Filter! 
Use this method shown for smaller holes drilling in acrylic, always use a wood block beneath you can drill into so you dont split the acrylic.
Disclaimer: always use eye protection and safety measures when building diy projects, we are not responsible for accidents or injuries because of any information from this website or any associated, we offer informational services on DIY and all other sites. One must seek professional help on any project and never take on a project or process without full knowledge of all safety measures, first consulting with a responsible and professional for products, advice or other questions.