Sump build

Ok folks I am new to the hobby and am currently running a canister filter on my 55. I am cleaning my canister regularly but would rather not have to wring out the sponges every week.
I am researching how to build my own 10-20 Ga. sump. I have a few questions.

1- what size sump is preferred for a 55?
2- should I go with a refugium style or use the mud? Do you have to have lights on the mud?
3- what is the least expensive quality pump (do those words belong in the same sentence)?
4- suggestions on how to make the water flow silent?
5- I currently have a Red Sea prism skimmer that I want to incorporate into this build. Any suggestions?

Basically guys I'm pretty cheap and looking for the biggest bang for the buck.

Thanks for the reply. Very helpful.
I have one more question to throw in-
My tank is not drilled. Could I lower the water and drill it safely?
Is an HOB overflow even an option?

Thanks

I have drilled a few tanks but they were dry and tipped on their front. For a filled running tank, I would have Erik at Aquarium Creations drill it for me. He has all the equipment and tons of experience.

I've drilled tanks as well.  All empty though.

I would chance drilling a 1/2 full tank, but remember you'll have to be careful--putting too much pressure on one side can crack the glass. 
Access is another issue as well, unless you have lots of open space behind the tank, you'll have to drill from the inside, which on a 55 doesn't give you much space to work with, and make sure you don't drop the drill in the tank. 
Especially if you are using a corded drill (since it can use up a cordless drill battery)!

If you really want a drilled tank, I bet you could find an empty 55g cheap and have it drilled, then swap over into that tank on a weekend once it's ready to go.

I've made several sumps of varying sizes with various materials.

First, I'd go with at LEAST a 20g tank. You'll need enough room in the sump for your 55g to drain. A 55g tank is 48" x 12"...and let's just say your drain is 2" below the water surface. That means about 5 gallons of water will drain into your sump when you turn the pump off...so you can only have less than 5 gallons of water in your sump normally. That's not a lot, and it doesn't leave any room for error.

Acrylic sumps are nice (I built one for my 200g system), but if money is a concern, you can build your own sump with glass for very little. I do not recommend acrylic baffles as they do not bond well with glass. Over time, you'll probably have a few baffles pop loose. I know acrylic is convenient, but local glass shops can custom-fit baffles for you for next-to-nothing. Here's a link to my glass sump build:

http://www.reefdup.com/2012/05/25/diy-glass-sumps/

I've never used the refugium mud. I've always run a standard refugium with no problems.

If you're planning to stay in the hobby, buy quality first. I bought all cheap stuff when I was a starving college student...that was a mistake. I ended up having to upgrade equipment very quickly and ended up paying a lot more in the long run. If you aren't sure about the hobby...then that's understandable. Harbor Freight usually sells pond pumps starting about this time of year for next to nothing. They're ok...they'll get you started. When you can drop a little more money, I'd go with an Eheim. Whatever you do...stay away from the Mag-pumps. They'll break the day after the warranty ends...not kidding.

What water height does your skimmer need? Again, if you went with a 10g sump, there is no way the skimmer would work with only 5g in the tank.

Edited by ReefdUp - January 13 2014 at 8:54am

Oh, I should mention...

If you get a pond pump, if it has metal screws, they may not be stainless steel. Just change them out...easy.