Hehe. I know. Try sitting in my shoes trying to solve this. I did shut the pump down and re-checked all of the connections. It might be the flex pvc, but I put so much pvc cement on the joint that I doubt any air could get through there.

I looked closely at my coral frag tank and there are bubbles going through the return there too, the water is just going so fast you cannot see them and they go to the surface pretty quick in there.

I will put a bright light on the sump and see if there are any bubbles getting to the intakes. This new pump draws more water than the old one so maybe it is somehow causing a stronger current in the sump and pulling the bubbles in.