OK, here's the update for the weekend:
Got the tank trimmed out on the front side. The trim around the tank sits flush against the glass and is removeable (for cleaning & tank inspection) by just popping it off. I used some of those screen door holders from the hardware store to hold it on.
Next up was water testing the sump (never got around to it when I built the thing). Went mostly well. Found an internal baffle that I hadn't glued all the way as well as the plug in one of the expansion bulkheads at the bottom was leaking slightly (needed some more teflon tape). When full the only deflection I got was along the back by where the return pump will go. It wasn't a lot but I had an idea to add a mounting bracket for all my dosing lines anyway so I made it so that it would serve as a reinforcing piece as well. Check it out in the second pick below (look for all the airline tubes going into the sump).
I also added another bulkhead near the top of the sump to take advantage of a "hole in the wall" I had from the last tank. This is an emergency overflow is case "something goes horribly wrong". You can see it and the 1/2 clear drain tubing in the second pick below.
Once I finished up the sump I brought it back in then plumbed it to the tank. I'm running the 3-pipe Herbie/Bean overflow system...the first vertical pipe is the siphon, second is the emergency overflow, third is the trickle pipe. The clear line at the very back is the return pump line. I really like that all my plumbing is constrained to these vertical runs. It's a far cry from my closed loop/Oceanmotions and external return pump setup from before.
Here's the shot of the plumbing as it hooks up to the overflow (the MP40 that's still in the bubble wrap will go under the overflow in that big cutout area). Also note the overflow cover(s). The black acrylic cover on the overflow slides off and will help keep things mostly dry around that part of the cabinet. A.G.E. did a bangup job on it - its got routed slots to make a better seal with the overflow. On top of the acrylic you can see that part of the wood shelf above is cut - this is because I made it removeable so that I can get into the overflow for maintenance. Details like this are where a scale drawing of everything becomes a necessity before you begin!
And a little lower down looking at the sump (that filter sock is gonna be a breeze to change!). You can also see 1 of 2 vents that I had previously installed. These vent all the way to the top/back of the tank into the dining room.
And with everything put back together (that wire is from the lighting...I haven't coiled it up yet):