I've managed to read 102 pages of the thread (first 40, and 62 of this one).
If someone can correct where I may be mistaken, it'd be awesomesauce...don't ask.
110g (or 120g) tank. 40 gallon sump.
1" schedule 40 bulkheads
1.5" piping.
Eheim 5000 return pump.
1" return hole(s) as recommended by Uncleof6.
30" Inky Style Overflow box, From top to floor is 5.25"
From Bottom of Trim to Emergency and Open Siphon = 2.25"
From Bottom of Trim to Main Siphon = 2.75"
If I'm understanding correctly, as described above can dish out in the vicinity of 2,000 gph.
The biggest question I have, well there are 2....
1) Will the pump I've settled on getting suffice?
2) Should i run just 1 1" return line, or T it off to each side of the tank?
I am planning on having the emergency pipe above the water level of the sump so I can audibly hear if there's an issue.
The open and main siphon will then be 1-2" below the sump water level.
Am I at least on the right track, or am I forgetting about something?