Thought about just going with it as it was, but luckily this happened:
Here is the rest of that thread....
http://www.canreef.com/vbulletin/showthread.php?t=72026
Lucky only because at this point I was ready to finish it up and start stocking it.
Some pics of the second attempt to make the overflow work to my satisfaction:
New Pump
Original plumbing
Rocks stored with heater and Koralia 4 , plus a carbon filter and frequent water changes to combat the Cyano
