Here's a bit more detail on what we've done to get the tank back up and running.
After we drained the tank on 4/24, we did a clean up job. This involved using the shop vac to pull out all remaining water and sand, including the closed loop. A neat little trick we discovered was to run the OM4 allowing it to roll through all the CL outlets, while using the shop vac to pull the water out. This is a really convenient way to drain the CL pump, intake and all four outlets without having to disconnect anything!
After getting everything vacuumed out, we used R/O water and vinegar to wipe down all the surfaces inside the tank, then a couple of rounds of just clean R/O water to rinse everything down. Then the shop vac is used again to dry it all out. This was the prep for the repair of the overflow box. The repair happened on Monday 4/25, went very well, and we braced the overflow box with a length of 1.5" PVC pipe. That remained in place until Friday 4/29 to give the silicone plenty of time to cure.
This Friday, we cleaned up the mess left from the overflow repair, and then did a leak test. This was accomplished by blocking the drain holes, filling the overflow box with R/O water, and then waiting for while checking for leaks. The repair was well-done. Not only did we have good structural strength, but no leaks. The only downside to the repair was the use of clear silicone rather than the black silicone that the factory used. A minor cosmetic issue that hopefully won't be noticeable. With the water test done, we then flushed the drain lines and return line with R/O water, and did one last wipe down.
<a href="http://www.flickr.com/photos/terryl93/5677482675/" title="nt 1037 by terryl93, on Flickr"><img src="http://farm6.static.flickr.com/5187/5677482675_c3562f7a19_z.jpg" width="640" height="425" alt="nt 1037"></a>
A bit of closer look at the repair job. This is the left side of the overflow box (we GLOPPED the silicone on - no more failures please!):
<a href="http://www.flickr.com/photos/terryl93/5678046540/" title="nt 1058 by terryl93, on Flickr"><img src="http://farm6.static.flickr.com/5106/5678046540_a55b09a2e2_z.jpg" width="640" height="425" alt="nt 1058"></a>
As we mentioned a few days back, one of the bright spots in this latest problem is that we have the opportunity to re-work the CL outlets. We we looking for some fittings to use in the back two outlets that blended into the background exceptionally well, but also provided great flow and allowed us to direct the flow where we needed it. After playing with several prototypes, we came up with something that looks a bit like a Texas hood ornament!

On the front outlets, we up-sized to the larger flared nozzles, and added some length to be able to curl them up and contour to the bottom of the rock scape. Here's a look at the left side:
<a href="http://www.flickr.com/photos/terryl93/5677484247/" title="nt 1039 by terryl93, on Flickr"><img src="http://farm6.static.flickr.com/5028/5677484247_7fecdd419b_z.jpg" width="640" height="425" alt="nt 1039"></a>
Right side:
<a href="http://www.flickr.com/photos/terryl93/5677486351/" title="nt 1040 by terryl93, on Flickr"><img src="http://farm6.static.flickr.com/5061/5677486351_ab11c220fc_z.jpg" width="640" height="425" alt="nt 1040"></a>
Saturday was
BUSY BUSY. As Terry mentioned, we had some awesome help moving everything back into the display. We had made up 180g of fresh salt water mix. This was because the water that went into the 180g stock vat where we kept the fish all week had become quite polluted (PO4 was measuring 0.55 - ouch!). So we moved all the live rock back, rebuilt the tree structures, caught all the fish, released all the fish, moved all corals, scooped all the sand, you get the picture. Tons of work. :hammer:
Here's how it looks right now: not too shabby, but the corals are not real happy with us, and a few of the fish are pretty beat up too:
<a href="http://www.flickr.com/photos/terryl93/5678146248/" title="nt 1069 by terryl93, on Flickr"><img src="http://farm6.static.flickr.com/5225/5678146248_0359fec44d_z.jpg" width="640" height="425" alt="nt 1069"></a>
Now, its time for champagne to celebrate getting back in the game. After all, it's not how you fall, it's how you get back up...
:beer: