After reading this thread- I have 2 thoughts to problems that have come up.. In skimming, i haven't seen these answered- though i havent' read every RC thread....., and they are what I plan to do on my next tank...
I can post pictures later....
1- the use of elbows..
I think more bulkhead space is by far the best way to go. but.
instead of an elbow, you can take pvc pipe [cut in half] or acrylic, etc, and silicone a lid from the front to the back wall of the overflow, leaving just the bottom open, [and the air vent hole to prevent siphons]..... this can work in any depth of overflow, though instead of leaving 3" or so for a elbow- you could keep the box to 1" or less [or the tilted one piece box]
2- the problem with leveling the top lip of the overflow.
Why are we locking ourselves into an overflow lip that is set once when the box is built, that does not account for different tank placement in the future, or a floor slightly tipping over time?
The solution I have found was to build the internal overflow out of glass, but leave the lip about 1/4" or 1/2" or so lower than the intended surface of the water. Then, you can take a piece of acrylic as long as the box inside the box, and clamp it on/ wedge it in [or silicone it] basically creating a movable and tunable lip. I have seen ranchers control lake level with a 4x8 board a the top of a dam- with many holes in it- in our tanks, at 1/2" underwater, there is not much pressure on the movable lip, and one would have to keep the true lip high enough- that if a leak would start- the sump could absorb it.
I think it is a waste you time pre measuring and pre filling the tank, when you can leave yourself with options, and a way to tune the overflow surface.
also, with wave boxes- one could taper the movable lip on each side- or even have 3 movable lips.. horiz in the center, but tilted up on the far sides [on the sides- possibly the only good use for teeth as well] - to quiet the wave splash, and stop the fish from being carried over into the overflow in a big wave [in full tank overflows]