what return pump are you using
are you running any reactors off the return pump?
what is the return pump gph rating after head loss?
i would recommend an eheim 1262 or ATB flowstar 1500 given your system volume - you can throttle them back with a gate valve if the flow is too much. Go with a Bean animal overflow system - this will require three holes for the overflow and two for the return. 1" should be good if you go with the bean animal - it allows for redundancy and is dead silent. 3/4" for the return should be good but if you check the pump specs it will tell you what the exit size fitting size is - if its one inch just use an adaptor to bring it down to 3/4 so you dont have giant return nozzles in your tank.
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