I used enkamat to silence the overflow on my old frag system and it worked well. Have you guys tried slowing the flow thru the overflow box to see if that helps? I know the shadow is rated for 1500gph but being on average 2-300gph below that I think you guys are pushing it a bit.
Enkamat is what ppl use to modify skimmer impellers for the mesh mod
Also, how far below the water level are the pipes in the sump? The full siphon pipe needs to only be an inch or 2 below, any lower and it is difficult for it to start the full siphon. Take a piece of airline tubing and stick it up into the full siphon pipe and see if air comes out of the tubing, if it does suck on the tubing to pull the air out and start the siphon if that's the case.