Well my overflow is centered on the back of my tank, which left me lots of room to drill the back of the tank for returns as well up near the top. I do employ a check valve to prevent back siphon as catastrophic back siphon would probably overflow my sump. I realize check valves are not perfect and can leak, but it gives me more than enough time for someone to get home and fire up the backup generator before it would overflow the sump.
It sounds to me like you want to create something like Randy's big display tank at ARC has with a side overflow that does not totally encompass the side of the tank and two returns drilled through the wall on either side of the overflow box. If you did it that way, you would have to make two more sides to your box, youd end up getting some extra length of overflow, you wouldn't have to worry about original silicone seams, and you'd be able to drill the sides high up for returns. Probably the best of all worlds if you can fabricate the box properly.