Salt E,
Your thread sort of got derailed with the brewery discussion. Amidst all of that was some great advice.
To get your thread back on track, here is a summary:
1. Your sump should never overflow when the return pump is off.
2. You can fix this several different ways:
A. Lower the water level in your sump, to allow enough room for the extra water when the pump shuts off
B. Drill the return pipes, just below the water surface, with siphon break holes.
C. Raise your return lines in the tank so they break siphon sooner (I think you did this).
D. Use check valves. This is the worst idea, been there, done that, they inevitably fail and you are screwed.
The best solution is to do something that requires no maintenance. So that means lowering the water level in your sump to make room for overflow water, raising your return lines in the tank, or siphon break holes in the return lines.