Morning Brad,
We have a 240g. I too didnt want to drill it, but I took the plunge and it is not that bad.
We have a 2'' overflow about 4'' from the top in the center of the tank. It flows to the sump in the basement.
The return pump is a Little Giant pond style (no oil fill) that I got at Lowes on sale for $129.00. It is 3900gph. I think they are around $180.00 now, but you can find them on Ebay cheap sometimes. Also, the Home and Garden shows are starting up for Spring and you might find a bargain.
I have a 2'' return with 2 ea. 3/4 valves in the sump. One for the skimmer and a second if I want to put on a filter or run carbon or who knows what other things come up. I could also pump it out that way too I guess.
The 2'' goes behind the tank and T's again. I have 4ea. 3/4'' valves that go to the back of the top where there are elbows on the 2 ends that shoot out towards the front corners. Then 2 more in the center that go down behind the rock and have T's to blow accross the back behind the LR.
My next one I would use 1'' return lines instead of 3/4''. Well now that you are totally confused by all that, have a great day
Chris