Todays challenge was the main overflow on the display tank.
BEFORE:
Two more holes cut for the extra pipes.
Unfortunately, I had a problem with two of the bulkheads. I cut the new holes with just a dremel. Actually only took about minute each to cut the holes. However, I couldn't really see what I was doing. One hole was PERFECT. The other hole was too big. The bulkhead didn't seal. I ended up cutting the hole even bigger and putting in a 1.5" bulkhead and then reducing it back down to 1". The original bulkhead in this overflow had to be replaced simply because everything was glued and I had to cut it out. The hole was perfect but the bulkhead wouldn't stop leaking. I changed gaskets and tried a different gasket - still leaking. I ended up just tightening the slightest bit and wiping off the water and then checking it again 10 min or so later and repeated the process until I finally got it to stop leaking but it sure seems like that bulkhead is now on too tight.
I also had to clean out the sump directly underneath the overflow box. I removed a baffle and threw out the sand that I had as a substrate in this sump.
Finally, on in to the evening now, and I get another overflow completed.
And once again - it appears that there is next to no flow in the sump because this thing KICKS ASS.
I think I mentioned earlier that this was going to take some time to adjust correctly. I was actually making a mistake at first. It's VERY easy to adjust and is actually quite forgiving.
I can't believe that more people don't go this route. I would dare to go out on a limb and say this set up is SO GOOD that eventually it will become the industry standard for reef ready tanks. Yes - it's that good.