Well the leak test did not go so well, but it could always be way worse!
I had two leaky bulkheads that simply required some tightening, which was quick and painless, but I ran into one more problem that has caused more of a headache.
My overflow box has a pinhole in the silicone that allows water to leak ever so slowly. Doesn't seem like a big deal, but when the return pump is off, the water leaking into the overflow from the DT keeps the box full enough so that water can siphon down into my sump from it. It's so slow that it siphoned about 3-4 gallons in 8 hours or so. Luckily I caught what was happening before my sump overflowed all over the floor. (This was the next morning when I woke up)
The effect of this issue is the DT draining into the overflow until the water level is below the pinhole in the silicone, which is about 10 gallons or so. The plan is to silicone the outside joint of the overflow box and see if this does the trick. If not I might have to rebuild the overflow box which I would really prefer not to do. I originally only siliconed the inside of the box, so hopefully I can get a good seal around the outside.
