Interesting read this thread Jim, I feel your pain on the sludge. My sump is rather rudimentary and piss poor. Big learning curve for me and I will soon be tearing down mine in favour of several canisters (I'm a sucker for an eheim bucket) until I get the greenhouse/pond sorted and will then go back to a sump. I know you blame your design but you can only design, try it out and learn mate, we're always learning. Said it yourself yours can't be too bad as your rays are clearly happy and reproducing.
Obviously each setup has its restraints with access and positions but I favour the idea of a settlement area, with a drain off point at the bottom to just crack the valve and remove the solids as frequent as you like.