I have a 180 gallon Marineland Corner-Flo and I am not a fan of the 1" ABS bulkheads that come with the plumbing kits. However I don't want to go down a size to 3/4" Sch 80 bulkheads. Is there a legitimate 1" Sch 40 bulkhead option?
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Bought the PVC ones for my tank and they work great, they are horizontally installed and no leaksschedule 80 fittings are WAY overkill for our applications and when it comes to bulkheads it's definitely a bummer having to shrink your pipe size with a predrilled hole.
Without going to Schedule 80, you're not going to get a lot better... but there are higher and lower quality bulkheads, even within the ABS Schedule 40 family. The ones BRS sells work pretty well. The Lifeguard Aquatics ones that Aquarium Specialty sells seem pretty decent. I'm with you on some of the kit parts... helped a friend set up a DBP 'reef ready' system, and ended up throwing their whole plumbing kit in the trash. Just cheap junk.
I'm using bulkheads that came from CustomAquariums.com... came with my H2Overflows and Siphon Stopper returns. I'm pretty happy with the quality of these, but their selection of parts is pretty limited. Oh, I'm happy with the H2Overflows, they work well. I'm _not_ happy with the Siphon Stoppers. Had to alter mine significantly to get them to work for me, and honestly, could have done as good or better building my own returns.

