ok kids down
talk to nano paul about glass if anybody on here counts as an expert about glass, he does. could also look at ada tanks of simular depths. still 1/4" is what they use on 10 gallons which bow, with a rimmless tank thats risky.
check ajmckays thread about doing a rimless for info on silicone.
http://www.nano-reef.com/forums/index.php?showtopic=209500 the thread you linked to is tigahs overflow thread near the end are pics of my herbie 10+10, which may help. just rember that what makes it work is pressure, which incresses with depth. if the back up is higher than there cannot be as much pressure to help incresses the flow rate. thus to have the same flow rate it needs to be larger than the point of restriction on the primarie drain. you may or may not have to use diffrent sized bulkheads. normally this is to much work but could allow for smaller hole which could be closer to the other line and thus fit everything into preexisting overflow.
this may help figure out drain hights
http://www.grow.arizona.edu/Grow--GrowReso...?ResourceId=188my drain is half of a 4" abs pipe as the overflow, no teeth. feeding 1"main w/ 1" backup. works great but water flowing over the weir is almost a 1/4" high. down side is that my clown ends up in there every now n then. sexy shrimp (befor it was eaten) was in there all the time (once a mounth). next time would double the size of the weir. down sides of teeth. double the distance needed for the weir, and can cause noise.
with what your thinkin of stockin the tank with minamize the flow rate across the weir to a trickle by incressing the langth.
forgot
look into using eductor nozzles to incresses turnover without flow through the drain.
one of the best diy rimless on here.
http://www.nano-reef.com/forums/index.php?showtopic=163883