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When I built the 20L sumps for my tanks, I actually brought the tank to the glass shop and left it with them to cut and fit the glass. I used 1/4" on both of them.
One thing you should have done was send 3 water samples out for testing: system, make-up and RO/DI.
First thing I would recommend is to switch salts. Seems like ESV is a common factor for several people with system problems and tank crashes.
What about running the ATO tube up to the tank return? I've done this before, run the tubing up to the overflow area, and the top off water goes right down to the sump. Just make sure the output to the overflow is well above the waterline.
Try putting the carbon on the bottom. If the media bags still get sucked up into the pumps, try putting a filter sponge under the pumps to hold the carbon down. Try to find a sponge that is not very dense, so it will not block the flow.
I smelled your pain!!! I shut down my reactor, I was planning to give it a cleaning, I let it sit for two days before I got a chance to clean it and noticed the pellets turned black. OMG that smell was beyond nasty!!!!!
Must be something in the water. I'm having the same exact problem!!! My A.Nana, pearlberry, Miami Orchid and Paradise table are all STNing from the base up. I've been watching my Alk. since it started a week or two ago and it has been pretty stable. I'm not sure what else it could be. :( It's...
Hang in there. It can sometimes be a rocky road and we all have come across our own issues. Twice now I've thought about shutting down and packing it in. Just don't be another guy that sells his tank, downgrades for a while, only to buy the same size tank they had from the start. It makes an...