Update:
This is the plan. I have found a 70gal acrylic, I've never used acrylic but I figure it will be safer to pit holes in? I will be picking it up this Sat. weather permitting.
Anyway, I will use my existing system as the fuge, removing all live stock, rock, and hydors. They will be used in the new display with some additions. I plan to put the fuge (with the macro from the old fuge) as close to the ceiling as possible, this will allow the pods and such to be gravity feed to the display. Trying not to blend them up, I will use a seperate "return" pump to feed the fuge from the sump, with lower flow. Also, some live rock, but I will be useing some "egg crate" and short peices of pvc to suspend the rock above the DSB. The 40gal has an established 8in DSB, with lots of critters, has a Current nova extreme T-5 light(6 bulbs, 108w).
The sump will be about 40 gal, 50 gal tank with 10gal for back flow. No baffles except for skimmer. This I have chosen the SWC 180 extreme cone, Thanks Skimmy! The ruturn pump, I have a Supreme Mag 9.5, after head loss I figure I should have alittle more than 10x. The lighting, I have chosen to use 2-Evo 200w 3G LED setups.(I can't wait to get them and power them up!!!!) Since I have chosen a smaller display, I will not be using extra LR because I have more than enough in my existing display, so there shouldn't be much of a cycle(hopefully). Water movement will be Hydors, not sure of how many or placement because I have to see how the rock work turns out, at least 4 of them. I will be using my wave maker from the old display to control the water movement.
The new display will have about 1-1.5in dry rinsed sand, no organics. The LR and the live stock(I have no fish only corals and 2 em crabs) will be put in the new display with the old water from the old fuge and sump(approx 40gal), and some new water. I will reuse the old water from the display after I relocate it higher.
I currently have a JBJ heater w/ dig controller and probe(300w), I think I will use the same just a little bit bigger since I can't find just the element. The controller is good for 1000w, I can't find just the Tit. heat element alone. So I will get a bigger one and save the old one for a future frag tank.
I like the Bean animal Over flow system, I will be cutting 3 holes, high in the back side.
Well I think thats the plan. If I missed anything PLEASE let me know, or if you have any suggestions PLEASE let me know. I could use All the help I can get, sometimes with so much planning and soo many things racing through the brain coral, I lose track. Once I get underway with real materials, not just thoughts, I will take some pics and post my progress.
THANK YOU TO EVERYONE WHO HAS HELPED AND HELPS ME IN THE FUTURE!!!!!!