I'm going to dissagree on too much surge, I've got a pretty good idea how much surge I'm needing (based on testing & referencing other tanks). It's not so much the glass I'm worried about, it's the limited section of silicone adhesion... If the 2.5g blew a seam with a 1g surge, I have little faith in those same dimensional seams holding on a 5.5 even with a minimal surge. Thus the reason for the reinforcing.
There are many ways I could approach building this, however as far as the tank, I'm going to run with what I know to work (I'm testing/tuning enough other theories with this tank). Overall design was done like this for two reasons, the full width overflow is sized to handle the surge of water (calculated flow) baffle system is to keep the water level at a minimum height, herbie overflow is used for noise control - may actually add a third bulkhead (base + surge + emergency). To me this is simplest/easiest/quietest way...
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