This is my theory & planned system:
1. High flow block, a lot of surface area and a decent amount of turbulence at the metal surface, just enough to break up any laminar flow - self designed.
2. Nice, big heatercore with either 2 120mm in & out, or 1-2 of the 24v Comair Rotrons(most likely) at 12v.
3. All tubing & barbs will be at least 1/2" - no hard 90deg turns.
4. 700gph Danner Mag Drive Pump (Pondmaster), NOT sitting in a res...
Now with the first 3 designed with greater system efficiency in mind, the heat from the pump can be a setback.
I plan on removing most of the pump heat from the water system itself. It will be a very compact internal closed loop system.
Before this gets fully implemented, I'm designing a WC system monitoring curcuit using a PIC MCU and I will be using the digital thermometers for more accurate readings. This might take a bit as I'm fighting bad computer addiction & slothic(new word!) lazzyness

and I have to actually LEARN PIC programming

But I plan on progress pics and temp measurements - flow is easily adjusted. I would like actual flow readings, etc.. but don't know how to implement that (cheaply).