JBendel: no apologies needed on the joke, it
was funny
The vent at the top of the durso pipe in the overflow was pre-made (I got the AGA Megaflow kit). When I cover it with my hand, the water level in the overflow drops very quickly... when I remove my hand, I hear a "hissing" noise from all the air leaving through the hole. So that part seems to be working ok, but I may be missing something obvious...
Bec: right, the 1.5" was my first attempt, I understand that going with a larger diameter pipe will increase the chances of getting this to work right... that's why I decided to skip the 2" size and go directly to 3", should be able to try that tonight.
Regarding the pump flow, the only reason it matters is that if the pump is sending more water up to the main tank, there will also be more water coming down to the sump, as the water level in the tank is fixed at the height of the overflow... so throttling back the pump allows me to reduce the flow to the sump and reduce the amount of bubbles as well. And no, I don't have a tank full of microbubbles
As for the cap in the vent pipe, I tried different things: uncapped, capped with only 2 holes drilled, with 4 holes drilled... all produced pretty much the same amount of bubbles, no difference that I could notice. If I cover it completely with my hand, I do get a lot bigger bubbles coming out from the bottom of the pipe, so it is doing something, just not enough.
The sump is in the stand, under the tank... fwiw, there is about a 1.5 foot horizontal offset from where the water leaves the tank (the drain bulkhead) and the place where the water enters the sump.
I'm going to try the 3" vent pipe tonight and will report back, hopefully with good news
Thanks for all the help and support, guys!
Nuno