So I will be upgrading my tank in the very near future here. Im thinking of a typical 220 (72"Lx24"Dx30"T)
Welcome to the wet armpit crowd. Have you considered flopping it sideways so it's 30" wide and 24" tall?
so my initial thoughts are:
a bean animal drain
I don't see the point in drilling an extra hole and doing extra piping. I've never even heard of a Herbie overflowing so IMO a Bean Animal is a waste of time, effort, and supplies. 
what size holes? 1.5"? for 1" piping or 2" and run 1.5" piping?
I'd do two 1.5" drains (bulkhead and piping) for Herbie, and 1" return.
current sump is a 40 breeder but I think a 75 would be a better choice.
Agreed.
the rest of my equipment will just transfer over.
apex, dosing pumps, top off pump, vertex in 280, snapper running GFO and carbon once in a while, and powerheads
I'd get a bigger/better skimmer, JMHO.
internal or external overflow? my only concern with an external overflow is fitting it through doorways......currently where I live my sliding door is 10' so not an issue but I dont plan on being here forever.
Have you considered false wall where it's an internal overflow, but it spans the full height/width of the end?
either way I would prefer the bulkheads out the back as opposed to the bottom.
Really? That just makes you use more elbows in the plumbing.
i have a canopy so I dont see the point in paying for eurobracing over regular trim since its hidden anyway.
Sometimes eurobracing is cheaper because it allows the builder to use thinner glass. I'd ask for a price each way. The nice thing about eurobracing (or trim) is that when you use a magnet glass cleaner you don't splash water where trimless you splash water easily. Drives me bonkers.
any comments, ideas or advice? it will be an SPS tank
Nice. 
Therefore, I want to push even more for you to upgrade skimmer.