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1) If the pump is rated for 700gph it will not come close to being enough for a system that size. You need at least 1000gph on top of that 700.

2) Not 100% clear on your drawing, but it is not wise to submerge the return lines. I know your sump is huge but your display tank will back siphon back into the sump to the first siphon brake/ first place air can get into the return line.

3) Can't help on the diy bulkheads, I have always bought bulkheads. Slip or threaded is a matter of preference and how you want or need to plumb your tank. Plan it out first, don't use threaded if you don't have room to twist a fitting+piping into it. You need to pvc cement on slip and teflon tape threaded. Use unions where you know you might need to remove piping and such.

Nice set-up, slow down, ask questions, you will be happy you set it up right the first time.
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