Hey guys,
I'm gonna attempt to answer the questions in the order they were asked....
how do you make the overflow box etc.
Well, to be honest there are several ways to do this.
In one version, you dont need an overflow box. The plumbing comes straight out of the tank, (either back wall or from bottom of tank in some commercially available models...marineland for example). ReefLady has done this on her tank at home. She has (I think, cant find the pics...going from memory here), three 90 degree elbows mounted to bulkheads in her tank. The elbows are at an angle and capped of w/ strainers/plastic mesh grills to ensure nothing gets sucked down stream that shouldn't. Her return is mounted the same way...just off the back wall of the tank. (edit...Reef Lady was kind enough to give her pics to show what exactly I'm talking about ...link in the post below)
I don't particularly like the Marineland version which is just a piece of Plumbing rising up from the base of the tank, the return is the same way. My rationale is this...anytime you make a hole in a fragile/ breakable material, (in this case glass), you weaken the overall strength of the structure. In most cases this is okay, Engineers are smarter than most people and they realize that the rest of us are generally gonna go do something stupid and test the limits of whatever it is they design, (like drilling holes in otherwise perfectly good aquarium glass). So they typically over-engineer whatever it is they plan to make...A friend of mine (who's a mechanical engineer) calls it the moron factor. According to Stuart, "If any moron can walk up to it, (whatever it is) and break it w/o half trying, you did'nt build it right."
However, w/ that big hole that is drilled thru the bottom of the tank and connected by a length of exposed plumbing, (which will act like a lever when you REALLY don't want it to) with no real way of protecting it should a rock tumble, your dogs get too rambunctious, you live in the great state of Confusion, uh...California, and have to deal w/ earthquakes, etc. I just don't like the lack of protection that the exposed pipe has. One fall/bend/twist etc, and bang, now you've broken the bulkhead that its connected to and your tank is draining out onto your floor, and ya can't stop that cause its on the bottom of the tank.
The overflows like RL hasdont really have that same problem. The plumbing attached to them is much shorter, (More force required to cause damage due to less leverage available) and they are mounted high enough up that if you do go all crazy and crack the bulkhead, you've got more time to find a solution. You will lose some water, but hopefully not nearly as much.
This is not to say that bulkheads mounted on the bottom are bad, I just want 'em protected by a nice wall...which (finally) gets us to answering your question....I plan on buying mine .(edit link in post below). I don't have experiance w/ molding/cutting or shaping acrylic just yet, so I'm cheesin out. Melev does some good work w/ acrylic and he might be able to help you out more than I ever could, (edit... just to be different... the link to Melev's site is in the post below)
i see that there's a prefilter in the overflow
Just make sure you can get to it for cleaning purposes. If you cant get to it easily, you won't clean it regularly, then it becomes a crap trap. Now instead of floating around your tank where it reminds you to get rid of it, the crap is stuck in an invisible spot quietly rotting and polluting your tank.
Hope that answers your questions Strat....
What is an optimum flow rate for the refugium. As a ratio so we can make it fit all tanks.
It really depends on what your doing...If you want contact time like I'm going for in order to export nuisance algae nutrients , I'm planning on at least 2-3 x tank volume an hour. So in my case (20 gallon refugium) 40-60 gph. I may decide to bump this up or down depending on my experiences w/ this set up. Right now, my refugium/sump has a turnover rate of at least 10x and I dont think I'm getting all the benefits of a refugium/ nutrient export that I could be. If your really suing it like a refugium and keeping somethin in there for living purposes, its needs will dictate.
Does this make sense?
Nick