ohiobart,
I have a 75 gallon tank too, and live in Ohio, but I don't get down to Columbus too often. Let's see if we can figure it out.
I think I'm understanding your situation, but i have a couple more questions.
Sounds like you have an external hang on the back overflow ??
When you raised the inner box up, you said the sump water level got too low and the return pump started sucking air and creating bubbles ??
That's exactly what one would expect, and it's not too hard to fix.
When you raise the inner box/teeth of the overflow, basically you raised the normal operating water level in the tank. The water level rose.
If the water level in the tank rose - that water had to come from the sump. So the sump level had to drop.
When that happens - the return pump may suck air and shoot bubbles into the display tank.
All you needed to do was add some more mixed/aerated saltwater to the sump.
You'll want to consider what happens when the pump shuts off too - and take some precautionary steps to prevent too much water siphoning back down to the sump.
Under most conditions - if you can see the tank water line when looking at the front of the tank - your tank level is too low.
If the water line is up hitting the glass - it's obviously too high.
Could be too high because your inner box is postioned too high, or it could be that there's a restriction in the overflow. If you see an air bubble in the U tube - then you probably don't have enough return pump flow - enough to force out air bubbles that can accumulate in the U tube. If the tankwater level is equal to the water level in the inner box - you've either got too much pump, or not enough drain.
Anytime we make a change to the pump or the overflow - we can expect a change in the sump level and how the system operates.
What kind of overflow do you have ? Rated flow ?
Are your using a sponge prefilter in the outer box of the overflow ? If so, do you clean it often ( weekly ) ?
What kind of return pump ? Flowrate ?
What size sump ( or is it a wet/dry ) ?
What manufacturer's display tank ?