Well, another slow day on this front...
I did get the return holes milled and the acrylic return tubes in place on the reservior. I also ran it with the top on and about an 1/8" of air in the top. The water was churning towards the pump side, but didn't draw in air at all.
I also received the copper for the video card and hard drive cage solutions... the smallest pieces are 4.5" x 4.5".
I will have more pictures tomorrow on the power supply conversion.