You don't necessarily need the pins, but they help the weld-on wick under the acrylic edge. With out you may not get the glue to wick completely. The weld-on will create a joint that is very strong, and if it wicks all the way through the joint as it should gluing both sides is not needed.
Have you decided on a return pump? I don't leave to much room in the return section, personally I would find out which return pump I wanted, and leave the section an inch or so wider then needed to fit it in there comfortably. This will give you the maximum space for a skimmer, etc. I would look at examples of sumps online and use that for a general judgement also.
Are you planning on making a bubble trap, like on melevs site where the return from the tank flow into it and then the water come out the bottom? If so just make sure it is higher then the baffles you use so it is above the water level, forcing the water to flow under it.
My LCD monitor blew yesterday so I bought my TV from my bedroom down to my computer. The screen is huge and after a few beers this is hurting my eyes now lol.
