Cutting glass teeth !

thats what I would do. just cut some lexan or use egg crate.

 

You can't really cut teeth in glass. When you put any pressure on the teeth glass will naturally break in the direction it is cut. So where the bottom of the tooth it will just break straight down. (Remembered that from highschool art class haha)

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I'll let you know how it works, but I'm building a new nano with an internal overflow and will use no teeth. I've done my research, and opinion seems to be that an overflow wall that's smooth glass will be fine. Apparently fish sense the difference in water pressure and avoid the wall where the water is rushing out and over.

Again, I've no experience today, but will have in the coming days when I get this tank wet. The overflow is built and I'll have pics on my build thread shortly. I'm finishing the plumbing now, and if all goes well, it'll be full tomorrow. I'm uploading about 45 pics to PhotoBucket as I type.

Back to the question--I got a good idea from Powerman that you can use that plastic trim (the stuff that's used to close the gaps between the back of a glass lid and the rear of the tank). Cut teeth into that trim, and sleeve it over the overflow lip and voila, custom made teeth. I decided against it at the 11th hour b/c I thought it might be an eyesore.

EDIT: OK, I'm a moron. Sorry I didn't catch this will be a baffle in a sump/fuge, and not an overflow box. Ignore my post about the overflow box, but perhaps you can use Powerman's idea about the plastic trim. Good luck.