I got a used 80 gallon from my lfs for cheap for my sump. Here's a pic of running spa flex from upstairs down to the sump and getting my baffles set up.
http://i1177.photobucket.com/albums/...umpre-seal.jpg

Water testing the refugium side of the sump
http://i1177.photobucket.com/albums/...mpleaktest.jpg

This Version 1 of my drain plumbing.
http://i1177.photobucket.com/albums/...thskimmer2.jpg

And from the other side
http://i1177.photobucket.com/albums/...ithskimmer.jpg

To get the right height for my skimmer I cut 4 pieces of 4" ABS and drilled a bunch or 2" holes in it all. I took all my LR rubble and packed it into them once I got the system up and running. And yes, that is the remnants of my under gravel filter I used as my skimmer platform :)

Here's where I finally had just fresh water in it trying everything and leak testing.
http://i1177.photobucket.com/albums/...umprunning.jpg

I quickly learned that because the water level in my skimmer section was lower than the water level in my refugium section it won the battle with gravity and I'd estimate 95% of the water goes to the skimmer section. Turns out that was a blessing in disguise. It first plumbed it as you see in the earlier post with 2 ball valves after the T. I never was able to balance the system out. I ended up cutting in a gate valve above the T and it works great now.

Next step was getting sand and salt water mixed up and in the tank. I went and bought 120 lbs of Tonga LR and because of time constraints had to just shove it all in the DT.
http://i1177.photobucket.com/albums/...Tsept26-11.jpg

It sat like that for at least 2-3 weeks. I ended up sticking 3 cocktail shrimp in there over that period. They totally disintegrated and dissolved in the tank and I never saw any ammonia, Nitrite or nitrate. To this day, I've never seen any of the 3.

Version 2 of the sump drain plumbing looked like this
http://i1177.photobucket.com/albums/...s/PA042084.jpg

and my first attempt at aquascaping which is pretty much how it looks now. Although I may have moved 1 or 2 top pieces
http://i1177.photobucket.com/albums/...atapus/fts.jpg

Within a couple weeks I had tons of weird little things growing and crawling all over the place. After 8 weeks I decided I was never going to see a cycle and got some critters. With the addition of a dozen or so snails and some hermit crabs I bought a Yellow watchman goby which I still have and a skunk cleaner shrimp.

http://i1177.photobucket.com/albums/...tapus/ywg2.jpg

http://i1177.photobucket.com/albums/...ingstripe2.jpg

next was a pathetic piece of GSP

http://i1177.photobucket.com/albums/.../starpolyp.jpg

Then came a peppermint shrimp and a pair of Occellaris clowns which to this day have not hosted anything :(
http://i1177.photobucket.com/albums/...apus/Nemos.jpg

A couple nights after I got the clowns the male decided to go hardwood floor surfing :(

http://i1177.photobucket.com/albums/...peppermint.jpg

I also got a blastomussa which I didn't know how to care for and pretty much melted with my MH's
http://i1177.photobucket.com/albums/...stomussa-1.jpg
It has since rebounded and is doing quite well now.

I also added a little zoo colony and a torch

http://i1177.photobucket.com/albums/...s/PB052211.jpg

http://i1177.photobucket.com/albums/...torchcoral.jpg

And here's a FTS after about 4 or 5 months. You'll notice a few other additions from what's been mentioned thus far.

http://i1177.photobucket.com/albums/...s/PB172253.jpg

With all that was going on in the tank I had a tough time keeping my PO4 under control, and my over feeding didn't help either. So I got a couple BRS reactors and started running GFO and carbon. I had a heck of a time with running the reactors with Maxijet's so gave up and plumbed a manifold off my main pump to run them
http://i1177.photobucket.com/albums/...atapus/2-2.jpg

Fell in love with this guy at the lfs so got him
http://i1177.photobucket.com/albums/...s/PC042282.jpg

Great job on the scape, lots of caves and places for coral.

Next addition was a starry blenny
http://i1177.photobucket.com/albums/...s/P3052534.jpg

A kenya tree. If you EVER think of getting one of these... STOPPP!!!! DO NOT GET ONE :D
They are constantly dropping arms all over and you'll never get it out
http://i1177.photobucket.com/albums/...s/P3052530.jpg

Thanks! I think when I re-do it I'm going to try for more of a two island look and more bare sand. Hard to do though with these tank dimensions. Trying to talk the wife into letting me go with a 180 but no go so far. :(