Thanks Dave! That's more or less what I did when putting two baffles next to each other, maybe you could use some kind of tool to smooth the edge where you can't get your hand in, something like a small rubber spatula...
My bubble trap is set up as shown below in the first diagram. The water's flowing left to right. I needed the third baffle so that water enters the pump chamber from the bottom to keep from agitating the surface where my auto-topoff will be. I believe that the second setup in the diagram may allow bubbles to spill over into the pump chamber, and the third, while an effective trap, would agitate my surface water and drive my auto-topoff crazy. (thanks for the tip Chuck!)
After a good night's rest, I've decided to keep my siliconing job on the sump and be proud of it! It looks a little rough, but it is very solid and will definitely do the job. I still have to add one more baffle (gotta get some more silicone first).
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