Hey gooliver and others..the adventure continues. What is the saying this hobby requires patience? Not me, at least not tonight with disasterous results.
So I moved around some plumbing in the basement to insert a ball valve to try to slow down the flow upstairs to see if it would quiet the drain. Was able to insert a new ball valve, everything on the return was snug, or so I thought. Turned on the pump, there was of course some leakage as I thought tehre would be, but when trying to adjust the ball valve BAM the pipe came loose and I had tons of water flowing into my face. Quick turn off the power switch...
Round 2: Use duct tape as a temporary means to hold the PVC together on the return. Turn it on, asking (yelling) upstairs for my wife to tell me if it is any quieter, she is watching TV and no help at all. So I'm running back and forth between adjustments... On the 4th adjustment, there is a muffled POP, the middle return tank flashes with blue light...power shuts off (GFCI breaker)... turns out when the water shot out in the 1st round, combined with the leakage that was controlled but significant int he 2nd round, water level fell below the water heater, which I forgot to turn off! So at some point it turned ON, glass cracked and POP everything went out on that circuit.
Anyway lesson here is I think I'm putting my heater not in the return chamber, probably in the PS chamber. Another lesson think things through, and yet another nothing I did seem to have a huge impact on the sound, or at least that's what I think. So I did all of that perhaps for nothing.