Curt,
just finished reading the last 10 or so pages of this thread and, well, it's been an interesting ride so far
because i know what equipment you're using on your reef, i have been highly interested in seeing the finished product. first of all, visually it is very impressive. wow. you have clearly spared no expense, which is the way to go if you're going to do it once (no point in wasting money on something you'll be replacing in a few years). it's great seeing someone making the committment to their life support instead of saying 'i'll only spend this much on my equipment so i can get that $200 frag right away.' then when it doesn't survive, it's 'well i better get another $200 frag so i can replace the one that died' not realizing that often it's the equipment that's the weak point. OTOH, there's no substitute for proper husbandry. which brings me to Mr Schiemer.
although he might have come across a wee bit harsh, Greg is a brilliant aquarist, and has probably forgotten more knowledge about reefkeeping than i will ever have. his point about the bulkhead placement is a legitimate one, and became a very real issue on a 3500g reef system that Mike Paletta and i consulted on. the tank was built by a custom builder, with bulkheads drilled in the bottom and lower back, even though we stongly urged him not to do it. ultimately, the tank started to split, and needed to be drained. although top quality ball valves were used, after only 10 months they had calcified to a point of failure, which Mike and i discovered the hard way. Deltec is making a new 5000g system for this client, and, as it has since they first started making systems, taking the pipes over the top, down the back, and out to the front for the closed loop. the nozzles point back to the reef, and with a bit of creativity, can be hidden with rock work. i don't know how you can add a preventative measure to the lower BHs, but if there's a way to do it before your system gets too established, i'd highly recommend it.
thanks for keeping us involved with your reef:thumbsup:
Doug