Why not go for just 10x into the sump? And use powerheads or a closed loop for circulation and water flow.
I'm a believer that water flowing into a sump (what you're talking about is not really a sump--it's a refugium because you're using it to grow food and fauna) shouldn't be the same speed as you want in your tank. Crank 2400GPH through your 40g sump....... Can you say tidlewave? How about garbage disposal? Whats that? --- carry the two.... add the zeros.......divide by 4....... that's 60x through your sump full of crabs, snails, other inverts and the skimmer. There's no dwell time in that sump/refugium. Your snails could reproduce in your refugium. That would feed the tank. Maybe thats your plan all along? It ain't gonna happen at 60x. Eggs will be washed away. I'll bet you wouldn't have many pods in a refugium like that. It's too fast.
I'd shoot more for about 400-600gph through the sump and do whatever you need to do in the tank for circulation with the powerheads.........or drill about 15 holes in the back of it and slap a Dart on it :mrgreen:
If I ever get my 90g set up, I'll be drilling so many holes in the back of this sucker, people will think it's Swiss cheese. I don't like the look of big J-tubes or massive overflows on tanks. It works, and ya do what ya can. But I am determined to save up the cash to drill all those holes and buying the pump/plumbing setup. It's so much cleaner inside the tank. Use a 2" deep x 3" wide overflow across the whole back of the tank and couple 1" pipes to run down into the sump. The return pump can then be smaller. Smaller = cheaper and less heat into your tank. Unless you plan to plumb the return pump outside the refugium? That's what I'd like to do. Pumps wear out and big reef tanks aren't something you jump into for a year or two and then quit. Usually by the time you jump into the 100g club, your SERIOUS and will probably stay in the hobby for many years. You could be changing pumps at some point. I want it easy to access. Put a valve outside the tank and plumb in a union and the external return pump. When it goes out, it takes an hour to fix it. Maybe less.
I hope that I don't sound like a jerk. Just thinking out loud.