UPDATE TIME: Here we go!!!
Before I get to the good stuff (cabinet, yes it's finally installed


) upon the return from my trip I started playing around with the overflow design, needless to say I'm chalking it up as a failed experiment, I'm sure I could have eventually made it work but frankly, I didn't want to deal with it anymore.
So I bit the bullet and purchased an Eshopps PF-1000 (900GPH) dual 1" HOB overflow box. I glued my 1" piping into the bottom of the bulkheads to make it leak resistant, and replaced the 1" pvc standpipes that came with the unit (they were loose) with a nice snugly fit 1" PVC 40 pipe that were cut 1/4" higher (more water).
I also decided to split my return line to further create some movement within the tank, I used 45degree elbows and 1" pvc, glued it all together, leaving the 90 in the tank loose so I can redirect the water flow, and painted it all black. The following pics were taken after the piping was submerged in water for 72 hours to leech any paint gasses and bad chemicals off it. Used Krylon fusion to paint the PVC.
Overflow box & return lines hanging on display tank. Back of the tank, none of this will be visible.
View from the pipes & overflow from the front in the tank.
Overflow piping being glued in, bottom overflow shows the final length once all the adapters are threaded in this was so I can attach flexible pipe to the barb fitting be able to remove it (all this will be located in the lower portion of the cabinet). All threaded fittings were PVC glued then quickly threaded together, I couldn't find any barbed to pvc pipe connectors so this was the next best bet, it should never come apart.
HERE YOU GO! My cabinet, finally installed and standing, this is showing the tank in place (don't mind the cord, it isn't there anymore), it's built out of plywood with a stained maple veneer and solid maple doors, all the doors are piano hinged together so the entire unit can be opened up for total access.
Inside the cabinet, as you can see it's all open, no intruding legs or anything, this cabinet really was built with expandability in mind. The two galvanized supports you see are rated up to 600+lbs, the entire unit was designed to be supported from the two sides and back transferring the weight down to the floor, the cabinet sits on 6 adjustable legs also rated for the weight.
I wanted the cabinet to be entirely self sustaining, I don't want to see webs of wires behind it running to an outlet, so with the direction of an electrician friend of mine, I installed 2 PVC receptacles that run back to a wall receptacle outside the cabinet. One wire is better than 8

. I also mounted two power bars which will run all the equipment and allow for expandability.
Test fitting the overflow and return. These will be accessible from the sides and top of the tank.
And finally, a picture of the top and bottom plumbed, wired, and ready to go. I made a rookie (and possibly sleep deprived) mistake, I overtightened one receptacle cover, sure enough, SNAP. Ohh well a $1.25 mistake.
As you can see all the flex hose is plumbed and ready for the sump to be transferred into place. I need to pick up some rigid insulation to place below the sump still to help keep all noise to a minimum, I should have the Display Tank up and running by this weekend with my aquascaping done
My order of rocks and chemical should arrive by this Friday. It's nice to hit this milestone as the next one is when it really gets interesting, seeing the tank cycle, adding in livestock/sps corals, and finally enjoying the fruits of my labour.
Hope you guys like it, my wife and I do!