Update:
Many delays, none due to complications with the setup though.....
New 20A circuit was installed with a couple gfi outlets dedicated soley to the fish room.
Purchased 8 15lb bags of Caribsea Aragonite special grade seaflor substrate and 2 20lb bags of live sand (forget the brand...not aragalive) from That Fish Place. Headed home, rinsed the aragonite "dead" stuff thoroughly using the pillowcase method and began filling the tank. The rinsing method was the best move......while I was rinsing it, it literally produced a milk-ish foam and run-off. I cannot even imagine what the tank would have looked like if I had put it directly in without rinsing. The rinsing took roughly about 10 minutes each bag of vigorous scrubbing until the foam vanished and the water ran clear.
I added all the sand to the empty tank, and the live sand to the 20g fuge in the sump placed plastic trash bags over the substrate and a glass bowl and began transferring pre-mixed salt water to the tank from the rubbermaid container. This process took 3 full days as I make more rodi water each night. The first night filled about half the tank and there was minimal cloudiness. I made sure I had 2 HK4's in the tank to make sure there was plenty of flow.....no sitting water. Water cleared up even moreso after that.......
Next night I filled the sump and started the Iwaki external pump (that thing gets pretty hot, is this normal?) and wow.....the flow was so great I had tone it down a bit as the two sumps could not drain into the middle "return" sump fast enough. I spent the next few hours adding additional water and tweaking all the ball valves to get a softer amount of flow into the fuge and the right flow into the skimmer and return tanks.
It's a *alot* of flow draining into these tanks and it's pretty loud...... I'm sure there is more tweaking to do. I have to admit that I was VERY nervous about the amount of turnover this thing was producing. Mostly because I wasnt 100% confident in my glass drilling and my plumbing abilities and all of it standing up to the amount of water flowing through them all......
I watched the sump like a hawk looking for inconsistencies in flow or any leakage whatsoever for the next few hours and noticed everything sort of leveling off and I began to breathe a *bit* easier. No leaks so far.....
I went to bed still a bit nervous though and woke up 2 hours later *thinking* I heard a sound......I rushed downstairs expecting to see water everywhere, but all was good. Woke up today with no change.
Hopefully by the time I get home, everything is STILL good......although I am a bit nervous still.
I'll post pictures of the tank and crazy sump asap.......
I still need to hang the Outer Orbit and get some live rock in there, but finally i'm making major progress.
Ian and Nate.....stop over whenever you can....