Ok, here's the latest.
I got home early enough today to do a little work on the sump. I built two more trays for the bio tower. So now I have 3 trays total. 2 shallow ones (2.5" deep) and one deep one 5.5" deep, all have inside dim of 12" x 12". The deep one should hold 3 gallons of bio balls. The top tray has a drip plate for a bottom, and this is where the mechanical filter cloth will go. The second tray also has a drip plate for a bottom and who knows what will go here... for now... nothing, but if I want to use it for something in the future, its there.
Ive decided to stick with just 2 trays above the bioballs, so the next part of this is to build the biotower itself.
This should be pretty simple, just a three sided box with a top (a 1" bulkhead fitting will be in the top if I can ever get one from Big Als!). Does anyone know a way I can build a bulkhead without waiting 2 - 3 weeks for one from Big Al (and please dont point me to that VatoElvis site)? Inside of the 3 sided box Ill have to glue some rails for the trays to slide onto.
The biggest question I still have is: What height should the bottom of the bioballs be from the bottom of the sump? If I can partially submerge the bioballs (and maybe bubble air through them to increase the bacteria colony) Then I can reduce the overall height of the biotower and stand. If I need to make sure that all biomedia is OVER the waterline then the height of the biotower and stand increases. The way Im thinking now, the best way to ensure a constant bacteria population is to have the bioballs OVER the water. If the biomedia is partially sumberged, the waterline will rise and fall depending upon the dynamics of the system, and cause the bacteria population to fluctuate.
Am I over thinking this?