I have this brainstorm to build my own protein skimmer. It would be for a 55 gallon tank that is not drilled. I would appreciate any and all tips and ideas.
Is it worth the headache?
I did a lot of my research for my DIY skimmer on ozreef.org. Ton's of links in the DIY section for that topic. I'm glad I built mine, as it gave me good practice for building a lot of other things with Acrylic, but it was a lot of time and money on something that doesn't skim too well. If you're just looking for a good HOB skimmer for your tank, that doesn't give you a headache, go buy one.
Also, read the Skimmer Design 101 that I wrote as well and it'll explain a lot. I'm going to say that you're going to want the 4" skimmer based on your 55 gal tank. And in case you have any questions about his skimmer, there's a 4 page thread over on ReefCentral.com's DIY board regarding the skimmer:
I tried to make one for my 90 actually i did. But it doesnt work as effectively as many store bought ones and it costed me about 200 dollars after all the prototypes and pieces of crap. I kind of wish bought one now but it wouldnt have been as much fun.