Well i week later ( and 3 failed attempts) the Res is finally complete.
No leaks and holds 1.7 U.S. Gallons
Fits into the case nicely and Pump fit in perfect as well.
I ended up going with 1/4 inch Plexiglass and used a plexiglass bender to make the main body, came out pretty good considering its my first time making one.
Used a 1/2 NPT to 5/8 barb hose to connect pump inlet, all other fittings are 1/4 NPT to 1/2 barb
I hope to post some actual flow rates later but waiting on rads to come in.
So far I am happy with the results
take a look and tell me what you think.
Aardil
http://members.cox.net/aardil/resrev3.jpg
http://members.cox.net/aardil/res3close.jpg