Here's my 60g rock/foam wall:
Marco Rock Rubble pieces were siliconed to 4 - 24" X 12" sheets of plastic canvas. Gaps were then filled with Pond Foam, coated with Zap Finishing Epoxy, then sprinkled with sand and crushed coral.
Vertical edges of the individual sheets were cut into an interlocking wavy pattern so as not to have straight-line seams between sheets. This worked out well, as you cannot tell the location of the seams.
Each section has an integrated return siliconed into it that ends with an FPT elbow. These returns will (hopefully) provide the desirable random flow throughout the tank. In the event that some directional adjustment becomes necessary for the individual returns, to customize the flow according to what animals end up where, (4) 1/2' loc-line MPT adapter fittings with adjustable nozzles can be screwed into the integrated FPT elbows.
There is also an integrated 36" spray bar that will provide surface agitation to promote oxygen exchange.
I doubt that I will have the time to start and maintain a build thread as I had hoped, since I just moved 1500 miles and am starting work on a very large project down here. I’ll try to post progress pics when I can.
Props to Kannin for showing the way, and to yousmellsfishy for the plastic canvas and wavy-seams ideas.