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I think I understand this issue. I have noticed the same thing with my sump baffles when the water level gets lower. The water flows out from the baffle instead of down it, and this causes micro bubbles and noise. You know what I've noticed cures this? I run my finger along the top of the baffle and whamo! the water now flows down it. Can't explain why, but it works. I know, its not a reliable solution but it leaves me to believe that friction may have something to do with it. Have you considered rounding out the edge of the overflow?
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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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