Louey:
Could make some comments about your leaks, relocation of equipment, plumbing, flow, pump, and tank issues, but I'll save them for now. Could have saved you the aggravation if you had asked before doing.
Let me address a couple of things for you. Some if not most have been touched by gschiemer though.
Electrical:
You found out the reason why I relocated my electrical outlets to as far away from water sources as possible. Glad you did the same. It will pay off over time as the equipment and connection won't get as much salt spray either. You will be amazed how much is there in your size tank.
Pump/plumbing:
These are a few pieces of avice I have gathered from doing this a few times:
*Always put a union right before and after each pump. It allows you to take the pump out very easily and not have any water problems. This is a must. You'll be surprised over the next year how many times you'll have to use them.
*NEVER NEVER NEVER restrict the output of a pump by turning down a valve on the intake It will kill you pump in no time and it will make the pump cavitate = noise/heat/bubbles/dead pump!!
*Always upsize the intake of any pump by at least 1/2" diameter. This is even more so with pressure rated pumps. Go up by an entire1" diamteter if the intake pipe is longer than 12" as you'd be amazed how much resistance that will cause = cavitation = noise/heat/bubbles/dead pump.
*ALWAYS use hard PVC for intakes to pumps if can help it. It may take a little longer to cut/measure right and to glue, but it will save you so many headaches in the long run.
*To maximize flow and minimize resistance, I always upsize the outflow of any pump by 1/2"-1" diameter and reduce it at the very end to suit your needs. This is even more so if you have more than a couple of elbows and more than 36" distance of pipe travel.
Flow/penductor:
I used a pair in my tank fromt he return of the sump with an iwaki 100. No question these things move some major water. I eventually took them offline for a couple of reasons. One is that the jet stream is extremely powerfull and will hurt fish and tear the tissue right off any coral as far back as 5 feet from it. I have a 10 feet long tank and you could feel the jetstream 7 feet away from it. The other reason was that even though they made great water movement, they restricted the volume of water I was turning over my sump.
With yours, I would take the 2 top ones in each side and put a 45 degree elbow pointing towards the bottom of the tank and connect them to them. The stream from the top ones will hit the stream from the bottom ones making some chaotic flow in the entire tank. I can guarantee you will not even need the tunzes after that. Also, keep them pointed all parallel to the tank and don't get the bright idea of pointing some of them in other direction across the tank and towards the middle.
Sump:
If you can, drill your sump towards the the very top and attach a pipe with a hose leading to a floor drain if you have one. When the sump overflows again water will leave via that drain/pipe instead of overflowing all over the floor. Also, using a filter sock right where your water comes fromt he overflows into the sump will allow you to reduce microbubbles significantly to almost none and also helps to trap ditritus. They are easily cleansed and reused too not to mention they are veyr cheap. I use the 25 micron ones and rotate among 6 of them.
Below is a link to a thread I made about my own set up in another site. Look through the pictures and use/copy anything that may help you. I did not invent any of these thingss. I just copied it all from other successful people.
http://www.reeffrontiers.com/forums/sho ... php?t=5253
Good luck!
PS: I did not reply sooner because today was the first time RDO notified me of an update to the threa
