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I don't know which overflow you got, but virtually none of what you said should be necessary. You should NOT use thread tape on plastic bulkheads, silicone thread grease is fine, but should not be necessary if the bulkheads are installed properly. Also,there should be little to NO noise from the overflow if set up properly as well. Get an overflow with at least 2 drains, 3 is even better. If there are 2 drains, you would set it up as a "herbie" style overflow. If 3, it would be a "bean animal". Both are virtually silent when done correctly.I just drilled my 75g over the weekend and put in a CPR something or other. 2 take aways make sure you silicon and thread tape the threads on the bulkhead(s). Also be advised they are loud. Research how to silence yours. Otherwise you'll have a draining bathtub effect. Also get a lid. A larger sump is better in the sense that if you have a lot of equipment and you want it inside the sump, you'll need space. Like I have currently a 20 gallon and it's getting crowded, therefore I'm getting a 40 gallon to go underneath so I gain more room. Hopefully I dont fill it up with gadgetry as well.
Okay still waiting to hear back about the one tank, It is drilled on the back. Has two holes drilled close together. Guessing for the overflow they had installed. Two holes at the end of the back near the top, Guessing for two return lines. That tank also was told comes with the overflow and is only 100 dollars.You can just do a google search for "bean animal overflow' or " herbie overflow". There is a TON of info out there.
The Herbie style basically uses 2 drains. One is set up as a full syphon and has a gate valve installed inline. The second drain is an emergency/open drain.
The bean animal is basically the same, but has a third drain, the secondary drain. This drain is used as a backup in case the full siphon gets clogged. In which case it becomes a full siphon.
DC pumps are more efficient than AC, usually quieter, and use less power. They are also controllable. It is not that DC pumps need battery backup while AC do not, but due to the power draw of an AC it is simply not done without a generator. DC is much easier to power for long periods on a battery where AC would only last minutes on even a rather large battery.

