Well guys here are some pics:
So the details, Mag 18, with 1 1/2 inlet piping, 1" outlet all the way. I did not glued the tank side of the U, but tightly dry fitted. The rest was glued, since the inlet of the pump is 3/4", I reduced it right at the pump. I was getting lots of micro bubbles, but the noise from the pump was killing me. Sure sounded like cavitating, not just sucking in air. The Chiller (Power Cooler 1/4hp from J&L) is supper quiet, compared to the rest of my system. My MAK4 and Iwaki 55RLT are no competition even in the cabinet.
So I have glued it all not, will wait an hour then try again, if that doesn't work, I just picked up more fitttings and will try to mount the pump way down by the sump, 4'+ of extra head
Lee