OK, drilling the final holes for my 55g
rebuild tonight. Here's what I'm doing.
38" x 6" x 4.5" calfo-style
overflow with 3x 1" bulkheads.
2 k3's mounted next to the overflow on both sides.
Panworld px50-x (1110gph) CLS. 1.5" drain, 2x 1" returns that split for a total of 4x 1" returns in the back of the tank. Each individual return is a 1" 90 degree facing the bottom of the tank behind each section of LR (floor sweep).
Mag 5 return, piping enters behind the K3 on the right side.
Total 60x turnover not including head loss.
BB tank, pillar style LR setup. using 1" cuts of 1" diam. pvc for rock stands.
Still trying to source some tan starboard locally... wish me luck.
What else guys, does it sound like I'm missing anything? Any flaws in my logic here?
thanks! oh yeah, pics coming soon...
I love to see people creations, im an equipment guy.....its sweet to see setups. Try finding a trophy store that makes its own cases.....they can probably get starboard for you. 
