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Everything is doing very well for me. Cuts are healed and things are starting to encrust. Most have colored up very nicely and a few are still coloring up more everyday.
Money well spent on a good tank. Of I had the cash I would do something like an elos or reef savvy. Like anything else you get what you pay for. You can buy a korilla powerhead or a vortec or a reef octopus or a bubble king. For what it's worth I have seen tanks from the run of the mill tank...
I'm not positive on the recharging of the resin but it you're having a problem with going through the resin quickly because of the excess CO2 there is a pretty simple solution. Simply run water through all stages except the DI and collect it in a container. Then using an air pump and air stone...
I think you will be fine with the 3 if you get the height right. One of the tanks I maintain is an 8 footer and has 4 Vegas over it and they have been working great.
Lol. It's definitely possible to get a Rubbermaid stock tank for all of your water, rock, livestock while you drill the tank. You should be able to knock everything out in 2 hrs max which would not be too stressful on your stock if you keep a heater and small powerhead in the stock tank.
I have no first hand experience with it so its hard for me to say. Do a google search of "drilling aquarium while full". There seems to be quite a few threads where people have successfully done this. The biggest issue I see is that there is stress on the glass from the water pushing out on it...
The fluctuations are not really that bad. In my opinion if you keep your temp within a very tight tolerance your corals and fish will become used to this and in the event of and emergency (power failure or heater breaks) they will be less likely to do well with any swing in temperature.