Well its running with FW in it right now and I only had a couple of small leaks and had to tighten a few fittings.
As far as the pump intake I thought about enlarging it but since the pump has only a 3/4 intake and it was straight I thought it wouldnt be an issue. It's only about a 12-13" run. Right now I dont see/hear any cavitation and seem to have more than enough flow. I had to make the output of the pump a 90 because with the straight barb the hose kinked real bad. I used hose for the intake and output of the pump to try and isolate any vibration and if I didnt like the pump I could change it easily. Not to mention space under there is tight because it was all originally built to have a submerged pump.
I am getting bubbles but they are coming from the pipes for the overflows. They seem to "boil" and stir up quite a few bubbles that make their way to the return intake. I dont know if I need to make them shorter or what but I didnt glue the last piece of down pipe so I can make changes to them.
The bottom of the stand isnt sealed though I wish it were, sorry first tank.

I have a CSS 220 for the skimmer and still need to build a place for it in the sump. I'll probably upgrade it later but a lot of people seem to like them for the money from I read. No vibration from the wood backing, the hose seemed to isolate it. The pump itself is a little bit louder than I like though. Maybe an upgrade to a Titanium one day, I just want to put something in the stupid thing that moves.
What is holding the flex tubing on the bulkheads?
Im not sure what you mean there. There is a bulkhead in the inner wall with a MPT/slip screwed in on the fuge side with 3/4" PVC pipe running to the other side of the fuge. Then another MPT/slip screwed in to the outer bulkhead with a 3/4" barb on the outside of the tank. I can try to take a pic if you like.
This was my first venture into PVC plumbing and the first couple of fittings were half purple and so was my hand. lol