So I did quite a bit of manual removal tonight. My question is, what about manual removal finally makes the game change and you finally get it managed?
When will manual removal not have to be a task anymore?
Is 50-60 astreas, 50-60 hermits, 10-14 Mexican turbos snails, tuxedo urchin, sea hare, some trochus/nassarius/ceriths (good amount of both dwarf and regular), fighting conch - enough to wipe out the hair algae once I remove as much as I can manually? My tank is 160g display.
Not all of those CUC are great herbivores. I don't think hermits make the best CUC, especially because they like to kill snails. Nassarius and cerith are mostly going to be cleaning your sand bed, not algae from your rock.
I think the most important part of manual removal is getting what you remove out of the tank effectively (something like an in tank polishing filter can be helpful for this, or siphoning out with a small diameter hose while removing), and making sure that what is left is relatively short. I think the astraeas and turbos are your best snails for HA removal. I recommend making sure that they are actively placed on where the algae is growing. My urchin was ignoring a patch of algae growing on one of my rocks, so I picked it up and placed it on that rock. A few days later, the algae was gone on that rock. There's cyano now though, and I need to do a blackout to address that.
I know you said you haven't had much luck with your tuxedo, but all I can say is that I have had luck with mine. You could try picking up a few more if you want to see if they help. Urchins eat a lot of algae off of real reefs.
Also, as they say on reef beef, the dishes are never done. What maintenance is needed on a reef tank changes as they grow in and mature, and the particulars depend on your system, but they are largely not set and forget. There's always some work that you're going to need to do. Hopefully they look nice most of the time, and your biggest concern with your corals ends up being that they overgrow each other and need to be pruned back.
(Also note - I have limited experience compared to others. I like finding people, like Ben and Rich and others who have lots of experience and listen to what they say. So take my particular advice with a big grain of IO salt).