Ok... now I'm looking at overflow kits from Glassholes.com (if you have a better suggestion please let me know).
My question is what size should I get for this 75g tank?
My options are a 700 GPH or a 1500 GPH.
I am planning on using my new Mag7 for a return pump.
Also, someone educate me... what size should the return pipe be? 1/2" ?
I like to go bigger on all mystuff(for expansion), so I personally would go with the 1500...but it do believe that would be overkill and the 700 would work just fine... chances are your overflow is only gonna run as fast as your return pump is(as it controls the flow) and depending on how far down you run your mag 7 below the DT's water line depends on how fast it pumps... mine runs at about 580gpg atm on my 55gal....
As for return pipe I used 3/4 pipe...if you had the space you could go up to 1" on the return, larger pipes create less friction. A 1" pipe wouldn't have much pressure at the exit but would be a higher flow rate. Just keep in mind a 1" pipe over a 1/2" will hold significantly more water in the pipe so you will need to compensate for this in your sump's max fill line which may drop your operating level in your pump chamber too low and lead to pump failure, extremely frequent top offs, or in my case lots of microbubbles. I personally could not use 1" pipe on my sump because it would leave the water in the pump chamber too low and I would have to cut my pump's return down to about 300gph to compensate for it(loosing all advantages of using 1" pipe).