Thanks Flanders. Yes it has been a very frustrating 18 months. I guess what I learned here is that even if you are doing regular water changes your levels could be off and we should continue to test and make sure everything is in check.
A few things:
True zero PO4 and NO3 are not great ,particulary for the corals you have. FWIW 0.02 to 0.04ppm PO4 and 0.2ppm NO3 work well for me in terms of coral vibrancy and minimal nuisance algae.Are you using gfo or other PO4 removers?
Feeding: more meaty foods like small mysis etc. could help.
GAC ,I know you want it for allelopathy but that might not be worth it and/ or necessary. I'd back off a little on it.
Skimmer?
Ro/di would be helpful
4 bulb t5 should be more than adequate for 9/10 hrs or so.
Harvest the nusiance algae from the fuge; go with chaeto, caluerpa , gracillaria etc. With undetectable PO4 and NO3 most desireable macroalgeas won't grow. Never liked 24 hour fuge lighting ,personally; I'd go with opposit photo period .
I don't think Mg or Ca was your problem. IME neither of those levels are going to cause the kind of issues you were experiencing.
I think your problem was something toxic from your water source that is being removed by your RODI.
From this experience I do believe it was the Mg and Ca levels. RODI has been used since April with no change in coral conditions. The leather was removed back in May and still no improvements. The only change that changed anything was 3 weeks ago, I corrected the Mg and Ca levels and almost immediately saw improvements. This leads me to believe that those were the culprits. I guess more time will tell.