SGT_York

Still Available.

Depending on the diameter of the pipe and head height.  

I wouldn't go less than 1.5" pipes on the return and no less than 1.5" on the open channel you can get away with 1.25 on the siphon, but 1.5" is easy to find the swept Y T's.

Friction loss is higher in flex pipe than in straight hard pipe but that doesn't factor into the elbows.  You can do the math with these numbers;

1.5" Pipe head loss (ft per 100 ft) .......... 2" Pipe head loss

GPM .... Rigid PVC .... Flex PVC ........ Rigid PVC .... Flex PVC

10 ............ 0.71 .............. 0.97 ................ 0.22 ............. 0.27

20 ............ 2.45 .............. 3.68 ................ 0.74 ............. 1.01

30 ............ 5.09 .............. 8.13 ................ 1.53 ............. 2.21

40 ............ 8.57 ............ 14.31 ................ 2.56 ............. 3.88

50 .......... 12.87 ............ 22.22 ................ 3.83 ............. 6.01

60 .......... 17.97 ............ 31.87 ................ 5.33 ............. 8.60

70 .......... 23.85  ........... 43.25  ............... 7.06 ........... 11.65

80 .......... 30.51 ............ 56.37 ................ 9.01 ........... 15.16

90 .......... 37.93  ........... 71.22  ............. 11.18 ........... 19.13

100 ........ 46.11  ........... 87.80  ............. 13.57 ........... 23.57

200

I recently upgraded to a 180 and need to sell my old tank.  It's a Reef Ready dual overflow 4' x 2' x 2' with a slightly deeper stand.  It will easily fit a 40GB sump.  There is matching trim for the bottom.

Asking $275 for both.  Much cheaper it you can pick it up (tri cities, WA)

I also have a Reef Octopus INT 150 with older style pump used for 2 years on my 120 worked great.  $100. 

Truck not included!

This is what it looked like when setup.

It has some minor scratches on the sides, 

Good comments, I always use a 2x8 for the main opening header board it will support a hole large enough to fit a 75G sump, 2x6 for a 40G breeder header.

Looks nice, I've had my jebao return pump running flawlessly for nearly two years.  They are great pumps for low head height operations, but they won't push much flow higher than six feet and you really need to run the 1.5" plumbing all the way to the tank to keep the pressure low.

+1 on the Aqua Hub just a basic level of handyman skills required and it works perfectly.  

Also a fan of no teeth.  Plastic gutter guard is the way to go you get much better surface skimming, the display level in your tank doesn't increase near as much as does with teeth, thereby reducing the required size of your final sump chamber.  

Another option you may not have thought about is a kalk reactor or stirrer.

Calcium reactors are for high demand tanks, with only LPS and two clams you can meet all your calcium and alkalinity needs with a simple cheaper solution.  The only downside is you can only dose up to your daily evaporation, and need a timer so it doesn't add the solution all at once.  It also raises PH and has worked great for years in my tanks.

Jebao is a great deal, but they don't work for high head tanks.  I made the switch from Iwaki/ Pan World pumps on my last upgrade and am very happy with my Jebao.  

How much head height do you have.  If lower than 5' try the Jebao out.

Awesome thanks for the notice.

For a budget this is the best deal I've found it is very reliable and simple to set up.  and it comes with two protected sensors for added reliability.

http://www.bulkreefsupply.com/aquahub-diy-top-it-off-kit-premium.html

For the not so budget restricted this one is great.

http://www.marinedepot.com/Tunze_Osmolator_Nano_3152_Electric_Powered_Dosing_Pumps_Top_Off_Plug_In_Units-Tunze-TZ4114-FIDPETPU-vi.html

I have found teeth more trouble than they are worth.  Toothless provides better surface skimming and is just plain easier.  I just build a table out of acrylic and PVC.  Literally a small table that sits inside the overflow box so there is just a 1/4" gap between the top of the overflow and bottom of the lid use PVC for the legs.  System works flawlessly no fish/snails inside the overflow, with a dark acrylic lid no algae grows there either win win.