OP --
This is like deja vu all over again. I'm posting a link to a GREAT discussion on this when I was planning out my tank last year. It has flow rates, number of drains, and some people's REAL LIFE experience with drain size and flow rates on their tanks.
http://www.monsterfishkeepers.com/forums/showthread.php?573991-Drains-size-for-540-Gallon
I ended up going with 2 inch drains on my tank in case I wanted bigger pumps later. I've had the tank up 3 months, and I now want bigger pumps--so I'm glad I did that. BUT, like "SEANBURCH" said in the discussion above, 1.5 inch would probably still work--but I don't KNOW. With 2 inch drains, I DO know.
What fishguy said about the coast to coast overflow -- I wish I'd taken that advice seriously when I was planning my tank. My tank would be cooler with a coast-to-coast inside the tank, across the top. Or even better, if you really have the room, coast-to-coast outside the tank. Only problem I can see with coast-to-coast is supporting the pipe. You really need to think about that. You don't want the weight of all the PVC pipe to be supported by just the PVC cement on your bulkheads--they might leak if you do that.
Midwest Customs makes nice tanks, shipped to you, high quality work. Chris built my sump, too. The way he did the sock holders on my sump supports the pipe, that was his idea. He also made me see the light about letting him build the sump, too. Glad I didn't go with a used tank for my sump for a couple reasons.
I run Herbie style overflows on mine, I'd have done Beanimal but didn't have room in the overflow towers I ordered. I had Herbie style overflows in my head, that's what I had Chris build, and that's what I got. Works great, dead silent, but I have to play with it sometimes. I THINK Beananimal is just as silent, with less adjustment on your part. I think "JC1119" has a beanimal and a Herbie, so he'd be the one to say how they work in real life.
But, you're gonna have to have all this figured out when you call Midwest and order. They've heard of Herbie and Beanimal, but they won't be able to tell you how to set it up, how it works, how the overflow should be, etc. You'll need to tell them that. They will know drain size and flow rate, though.
Here's a link to another tank build discussion by JC1119. I built my tank by just reading his, set mine up the same way. I'd never done a big tank, never had a sump before. I just read his tank build thread, thought about it alot, asked questions here. That was all I needed to design then order the tank, plumb it all up, and get it working.
http://www.monsterfishkeepers.com/f...23425-300-gallon-SA-CE-community-build-thread!!