Marcorocks sells reef mortar to build the structure. http://www.marcorocks.com/aquascape-supplies/e-marco-400/I have had to modify my plan for the overflows. It would have been fine if I was starting from scratch with frags. It became clear to me that attaching full grown colonies to the rock was going to be much more of a challenge. I'm going to have to choose a rock, drill a hole and place an acrylic rod that I can fit the coral on and then place it in an appropriate spot. So I'm not going to do a pre-fab construction around the overflows. I will do it rock by rock as I place the coral. I might apply epoxy to the overflows first though and cover them with sand.
As for the powerheads I have an idea that I will try out soon. If it works, I'll post it. If not...back to the drawing board.
Pretty similar to the stuff Tunze made their Tunze rocks out of. You could do a base form that could slip over the overflow, then build your aquascape from their. My concern would be long term adhesion to the acrylic with anything you might try to stick to it. But a Sleeve would eliminate that issue.
I know you see it done online but I know you and you are a long haul type of reefkeeper, not one that will be redoing this in a year or two.
The base would sit on acylic and the rods attached to the acylic in combination with the sleeve would be you building blocks
I am sure you hae a plan and have thought it through just thinking out loud
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