Drew,
I have a 50 w/ a 20gal sump, and that seems to work OK. It got a little crowded in the sump when I added a pump for a chiller and a pump for a refugium, but it all fits. I do have to watch water level carefully; there is a pretty fine line between too low for all the pumps and too high so that if power shuts off the sump can handle botht the main tank and refugium water drop (a very real consideration in southern CA, the land of deregulated, rolling blackout power.)
If I was to do it again, I'd go bigger, but this is working and it's a major pain to change - my cabinet's built over the sump.
Also, on the subject of overflow boxes: IMO, you don't have to have one in the sense of a normal box in a corner or back of your tank. And, if you find the drain to your sump creates a lot of noise and add something like a Durso mod, you will lose any holding volume advantage to the box. Several of us reefers have built combinations of water silencers and overflows that can eliminate the need for building a special overflow box. I believe Doug has archived many discussion threads that talk about this, if you want more info you can search this site. FWIW.
Glenn
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