-How do you calculate that your Voncanoes have a 13% air/water ratio then, and at what points in the skimmer does this apply? It seems to me that most get the best results when the air to water ratio is much higher than what I see in the Volcanoes... I can reference ATB's, ATI's, BK's, and KZ's on this. Besides, at one point or another, you are going to go over this 'golden rule' when you reach the neck and the water drains... does that mean than everything drains back into the body once in the neck? I have never seen that at least. In one of my skimmers with a 4.75" neck that gets about 1300lph of air going through it, small particles of carbon dust are plastered to the top of the lid, chunks of detritus, and I have seen amphipods getting stuck in this section as well (until they end up in the collection cup). I hear you on the whole 'adding too much air' part... if you add too much water, the density of the 2-phase mix drops... much like quicksand, and things drop rather than float... but I just dont see this point being approached. The skimming ability of the darts on only 12" bodies seems to be just fine... either by ReefFlo or ORCA. A Deltec has a higher bubble density.
As for swapping volutes, a 1.5" inlet/outlet is enough to go above what a dart does, but the pump needs more pressure handling. The hammerhead volute seems to have a larger in internal volume, which is perhaps the single easiest way to increase a pump's air handling capacity without needing a proportional increase in air. Its not so much the inlet/outlet, but the volume of the impeller well. The impeller from the hammerhead isnt needed though... the impeller from the dart can stay. Im not sure what the final result/solution for the dart 'enlarged volute' was... I think there was also mention of just getting a custom volute milled for the Dart with 2x the volume... perhaps the bolt pattern or other things couldnt be accomidated.