Well, it's running now, believe it or not. I had eliminated the durso yesterday, but still couldn't get it to flow. Tonight I eliminated the barb fitting beneath the bulkhead, and attached a 1.25" drain hose that came with my sump along with the 1" slip-fit bulkhead that came with the sump. Behold, it now flows. It's not pretty and it's very noisy without the durso, but it's flowing!!
Thanks for the help everyone, especially with my cranky attitude about the whole thing. Hopefully Jeff at lifereef will come through for me and I'll have a better, more trustworth overflow. I don't trust the DIY one yet ... this is the first time I've left the room in about 2 hours
Incidentally, I tried putting the durso back on and it didn't agree... apparently, the height of the inlet on the durso is just too high to allow for enough water level differential between the 2 boxes, knowing that the differential is what makes the water flow through the siphon tubes.
I could almost definitely run the durso if the outer box was deeper... unfortunately, it's impossible to get the durso inlet any lower, but without the durso, the overflow is keeping up for now.
The thing also won't run without both u-tubes... so it's apparently a combination of factors that conspired against me to make this issue hard to diagnose.
1. U-tube flow wasn't sufficient, and probably barely is now.
2. drain tube capacity wasn't enough.
3. Durso pipe inlet too high, can't go any lower
4. related to #3, height of outer box insufficient.
Also, the inner box is adjusted down the lowest level it can go. The water level in the tank is just a bit higher than I want, but it's very close. Unfortunately, the water level isn't in the range on the box that I had planned, so I'm not able to adjust the level any lower, but that's ok for now. Again, this is going to only run temporarily until the lifereef overflow arrives.