The elephant in the room is the over 1" piping on a 40 gallon tank. It's going to be nearly impossible to displace the air in the drain to eliminate noise and not push so much return pump flow into the display that the overflow box can't handle it and the tank will either overflow or the return pump chamber will empty. How you fix this is by running 1/2" on your primary siphon drain, a 3/4” on your secondary and a 1” emergency drain. This is going to be overkill as-is because you’ll probably be pushing less than 500gph to the display with the return pump. The goal was keeping air out of the lines. Having ginormous drains makes this impossible. You have no need to handle 3000gph return pump flow and as a result, you’re getting noise. I ran the exact 1/2 - 3/4 - 1 setup I recommended on a 100g with around 450gph return pump flow. It worked flawlessly and I never got anywhere needing the emergency drain and could easily empty the overflow box if I fully opened the gate valve on the 1/2” siphon. It was dead-silent when tuned. 1/2” -> 3/4” -> 1”. No doubt, no question, your problem is the size of the drains. They are WAY too big.