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That depends on how much flow you want going through the sump. If it were my tank I'd use a 1.5 inch bulkhead to allow for at least 1200 gph return flow. I'd use only 1 return, probably .75 inch, and go ahead with the closed loop. Did you check out the overflow and head loss calculators on Reef Central?
Another idea would be using half inch glass for the tank with no eurobracing, but its a lot more expensive.
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THE BARQUARIUM:
55 gallon cube - 50 lbs LR - ASM G3 skimmer - 30 Gallon sump - 22 Gallon refugium / frag tank - 4x 24 watt HO T5's - Mag 9.5 return - Pin Point PH monitor - 400 watt XM 20K MH in Lumenarc reflector - Dual stage GFO/NO3 media reactor - 6 stage RODI auto top up -Wavemaster Pro running 3 Koralia 2's.
Fully stocked with fish, corals and usually some fine scotch
http://www.canreef.com/vbulletin/showthread.php?t=55041
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