I just wanted to say thanks to everyone that contributed to the stickies on this page. I couldn't get my brain around the physics behind a sump overflow, but it's clear now that I've built one. The posted instructions were extremely helpful. I am still a bit unhappy with my overflow drain cap, but I can make improvements on that later. I went with a 1" pvc top skimming type overflow and so far it's working great. I tested every possible combination of scenarios from a pump failure/power outage to an overflow failure with no issues. I have some really nice flow in my tank from my Maxi-Jet 1200 powerhead, Emporer 400 HOB, and the return flow from my sump. I keep natives and it simulates a stream setting really well. I'll be sure to post some pics after I go collecting an get it all stocked up.
Thanks again.
Thanks again.