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I gotta be blunt. I get it, it's your DBTC frag and your rules, but with rules this strict, you're probably better off finding a select few reef keeping buddies that meet your strict requirements to bank your corals and swap amongst yourselves. I don't know you, I sometimes add some flavor to...

That's a buttload of frags! You're going to have to frag every other day soon to prevent them from attacking each other. ;)

Not ideal, but you can either crop the image a little bit to decrease the file size or change the settings to capture in 12MP vs 24MP.

Where was the silicon used? Silicon's ability to resist ozone really depends on the environment. Ozone typically will not have an affect on silicon in water or when in low concentrations in air. But if exposed directly to high concentrations of ozone or ozone with really dry air, it will break...

Appropriately sized UV sterilizer. Black out for 3-5 days (including fuge). If nitrates and phosphates are zero, bring them up to something reasonable can help. Blackout isn't always necessary, but it can definitely speed things up.

Did it look they were rotating/rolling over on an axis? If so, it's ostreopsis.

Perhaps KZ have created their GAC in a special manner that they recommend hot water flushing before use. However, that's the first I've ever seen any company recommend flushing GAC in hot water before use. If you do something to the media that you're not supposed to do and get unintended...

Is there a reason you're rinsing with hot water? Any source material that says you should be doing this? GAC is really only for use with cold and room temp water. As far as I understand, hot water can degrade and decrease its effectiveness...

Your gasket already looks like it's may have an imperfection in it. It's too hard to tell from the angle of the pic, but if the chip doesn't go too far past that first raised ring in the gasket, it's probably not your problem. After you hand tighten, are you using a channel lock wrench or...

Also, since the tank is away from the wall, if you just use the gasket that came with the bulkhead and not use that gasket sheet, you should be able to see if the drip is coming from the tank or the overflow box if you fill the tank up to the bulkhead with water again.

Put the gasket up next to the chip and take a picture for scale. Does the chip cover extend more than 50% the width of the gasket?

Looks like a 3/8" (maybe 1/2") push connect. Get 3/8" stem to 1/4" push adapter. Double check size before buying https://a.co/d/1NyA682

Some overflows (especially slim models) require that to be done to fit the standpipe. Here's a pic of my IM25 with a Marine Modular overflow.

You can cut the bulkhead as long as the bulkhead extends 1/8-1/4" past the nut after it's been tightened.

I usually drill outside to in, but I make sure to clamp a piece of wood on the inside of the tank to ensure I don't push through with too much pressure at the end. Also, on smaller tanks, it's hard to go inside to out because my drill doesn't fit.

The nut should never have a gasket on it for the potential of twisting or torquing the gasket causing it to not lie flat. Your particular bulkhead model would be even worse to have a gasket on it since it is not flat would mostly definitely bunch up the gasket or worse, tear it. The gasket...

That's one of of doing it, but there's obviously a reason for the leak. If you have the time and you're not in a rush, find where it is and it'll make you feel more confident of your setup. Plus, it won't look fugly with a crap ton of silicon.

You have a picture of those chips in the drill hole? How big are they?

Doh! Before I even had a chance to comment! Speciosa are my bane. The speciosa I have now in my tank is from Thinh at Coral Exotica. Mine is still alive, still waiting for the color to come back though. But it's still alive at least.

Can't find the marine modular instructions online, but here are three other manufacturer's instructions. All put the gasket between the tank and the external box and none on the nut. Marine modular will be the same...