NO Baffles. Just Weir's

If the sump has that much water in it when running, it will overflow if the pump shuts off.

Well the sump looks like it is designed for the water to go under the first baffle and over the second. Is the water going over the fist baffle? I would remove the second baffle and cut it shorter or just leave it out.

may give that a shot.

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As Jason said I don't believe there's water going under your first baffle and by the design it should be...Raise water level in sump, should be close to the top of second baffle...this will get rid of the waterfall...get rid of the filter pad

I live in Kelowna and have a very similar setup to what you have (135 gallon tank with sump). I built my own sump out of a 50 gallon breeder tank based on one of Melevsreef designs(http://www.melevsreef.com/allmysumps.html). Feel free to send me a PM if you have any questions or would like me to have a look at it. It would be great to talk to a fellow reefer from Kelowna.

pm'd

I think your baffles are backwards, or you need to put one more in so that the first one is an over. Mine is Over, under, over and works awesome without any noise or air bubbles at all. . If your first baffle is an over, most of the "chunks" get trapped in the first section, where your skimmer should be located.

http://i6.photobucket.com/albums/y24...da/sump006.jpg

Hmmm. From what I can see in the pictures of your other thread the feeds to your overflows are from the bottom? I've never seen that before and I'm not sure how common it is. Mind you, I've been in the reef hobby only 2 1/2 years. Maybe someone else can chime in on that.

FWIW, here's a pic of what I've got. That's one of those thick scubber pads. Helps prevent "****" going into the overflow. Probably no help to you though, if yours is fed from the bottom.
http://i23.photobucket.com/albums/b3...3/IMG_0807.jpg

I also noticed in your other thread that you had Fluval and Eheim canisters on your previous tank. Are you running those on this tank?
I see two grey hoses on the right side of your sump. Are these for a Fluval canister?
I run a Fluval 405 canister on my reef sump and I get microbubbles from it because it doesn't completely seal properly and draws in air.

Just throwin' ideas out there.

no the hoses are running to the uv steralizer and back. no filters hooked up to system at all.

I sent you a PM with some contact information but if your return pump is flowing 2700 GPH (the pump you have listed in your profile shows 2700 GPH) that would explain why you are having problems. A 2700 GPH pump is way too much flow for a sump return pump and would definitely cause the problems you are describing. Most people use pumps with this much flow on a closed loop system.