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Sounds like something is still blocking or impeding the muffler.
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Yeah it really does and there was a ton of build up inside that piece that connects the pipe to the pump i was almost certain that getting that off would fix it. Maybe I'll take it apart again and have a third look over to see if I missed something.
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I've also seen a thread where a person added a piece of hose to the end of the muffler, and fed it back into the exhaust hole on the collection cup. This silenced it quite a lot apparently.
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Hopefully I don't have to do any modifications - It was so perfectly quiet for so long! Even looking at the pump taking air in I can see that the air is being taken in normally but every 10-15 seconds there is an extra amount of air bubbles that get in causing this flapping noise.
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Your tank is still fairly young and going through changes, its possible something has built up over time or depleted over time. Have you done all your tests?
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Using the API Reef master kit I have:
0 Phosphate
0 Ammonia
0 Nitrite
0 Nitrate
310~ppm Calcium (Maybe a bit low... I have slowly been adding some supplemental calcium since i last took the test so I'll retake tonight)
35ppm salinity
I use RO/DI water as well