Weekend update:
I made a few changes to the plan.
Instead of a 3/4” return and a single Durso, I changed to 2 1” returns and a bean animal. This complicated the plumbing piece of the build but is obviously the right choice for a system of this size and that beast of a pump. Enlarging one existing hole (used a Dremel and it worked perfectly) and drilling 3 holes for the drain pipes is done, everything is cleaned up, and bulkheads are installed.
Instead of using my 93 gallon corner as a refugium, I’m going to use a 40 breeder. This is easier to plumb and easier to light (far shallower).
We made the stand for downstairs to hold the sump, refugium, and pump.
RODI is installed and the first 50 gallons are made and waiting.
I ordered 400 gallons’ worth of Tropic Marin Pro Reef, a Tunze ATO, 4 Hanna checkers, 80 lbs of sand (the rest will come in “The Package”), a few pieces of those neat LifeRock shapes, and a few more misc things. I also talked to Richard at TBS about customizing The Package.
Next weekend we need to move that outlet up and enclose it in a weather proof box, build and mount the manifold, plumb the refugium to be fed by the manifold and gravity-drain to the return section of the sump, drill the sump and attach to the pump, and start dry fitting the rest of the plumbing.