1. That depends on where those bulkheads are located. If they are in your overflow box, then you can shut off the return pump and replace the bulkheads. Other placements might make it impossible to get at the bulkheads without draining the entire display.
2. No. Standard PVC pipes are fine. As you aren't working with high pressures, you can use "class 200" pipe, which is thinner walled and easier to work with. "Sched 40" pipe is the stuff that is most common, but it is already thicker walled that you likely need. "Sched 80" is really heavy duty and would only be used if you like how it looks and have extra money laying around. Other people use "flex" type PVC....lots of choices.
3. Glue specific to the pipe you've chosen. For PVC, it is special PVC cement that is commonly available..usually grey colour or clear.
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400 gal reef. Established April, 2007. 3 Sequence Dart, RM12-4 skimmer, 2 x OM4Ways, Yellow Tang, Maroon Clown (pair), Blonde Naso Tang, Vlamingi Tang, Foxface Rabbit, Unicorn Tang, 2 Pakistani Butterflies and a few coral gobies
My Tank: http://www.canreef.com/vbulletin/showthread.php?t=28436
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