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hehe, thats alot of questions!!!
1) The biggest sump you can fit! The more water volume you have total, the more stable your system is.
2) I use 300 watts for my 95 gallon, you may want like 2 150's. Put these in your sump, mine are in the return section where it gets lots of flow.
3) Figure out what space you have available, design your skimmer and return sections, and whatever room you have left use it for the refugium. The bigger the better.
4) It's not the number of power heads that matters, it's the overall flow pattern and volume the powerheads can push.
5) Don't use a return pump pumping 2000gph!!! About 350 - 550 is all you want traveling through your sump or you will have problems.
6) No canister filters unless you want to use charcole once in a while, your use of it will be limited.
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