Refugium Design Assistance (w/pic)

So it looks like this thread is just gonna turn into my "Refugium/Tank Build Thread" Lol. So far I have my 40B tank (and a black background), and just today after work I picked up my 20L for the sump/refugium as well as a Pondmaster Model 5 for my pump - I guess there are perks to being a manager at a Pet Store...DISCOUNTS!

Anyways, with that I have a few more questions. I went out and priced the glass I'll be using for the baffles in the sump. Just would like to know the opinion of you people out there on the height of the baffles - 8"...8.5"...9"? I just don't know. Like I said earlier the protein skimmer I'm ordering works best in 8-10" of water so I'm leaning towards 9" for baffle height. So if someone could chime in...that would be greatly appreciated!

Also another question. The outlet on the pump is 1/2". For my return should I keep that 1/2" with PVC piping or should I run a coupler and expand it to 3/4"? Probably a stupid question, but I've seen people do it both ways.

So far in order to get the tank all set up, I just have a couple things left to purchase. My lights should be coming in Wednesday (again special ordered with a nice discount ) I still have to order the protein skimmer, and then I just have to scoop up my Eshopps overflow box. I'm building the stand on Sunday/Monday for the tank. I'm starting to get pretty excited!

Here's a picture cause everybody likes pictures!
http://i157.photobucket.com/albums/t70/griebs18/2012-05-14193754.jpg

 

I'd go on the tall side with the baffles. You can always put something under the protein skimmer to raise it but your screwed if it's the other way around. Many folks use the lighting egg crate under the skimmer to give themselves a little wiggle room...
But it's your design guy, you don't need to if ya don't want.

...and I would expand to 3/4", 1/2" isn't very big. but again, that's not gospel