1. What size sump should i use?
I would try to use the biggest sump that will fit under your stand and still be able to be removed when the tank is set up. If you DIY a sump then you can use a standard glass aquarium and install some acrylic baffles. http://samsreef.com/component/option,com_zoom/Itemid,27/page,view/catid,1/PageNo,2/key,9/hit,1/">(Here is mine)</a>
[B]2. What size return pump?[/B]
My preference is to use something about 3-5 times the display volume (per hour). With an 80g you want a 240gph to a 400gph pump. Just make sure it will push the height of your return. This slower flow through your sump will allow your skimmer to perform and will decrease micro bubble problems. Use some powerheads or a closed loop with a separate pump to acheive reef level flow. You will need a total flow between 800-1600 GPH (or more) depending on your animals you are planning. Note that this can be from mutliple powerheads or closed loop returns (not a single source).
[B]3. What size skimmer?[/B]
I would think a bit oversized but still able to fit in your sump. Maybe something rated for a 125g or larger.
[B]4. What kind of filtration?[/B]
Live rock and live sand. Maybe some carbon in the sump. Not much else needed if you keep your fish stocking levels reasonable and do not overfeed. Your cleanup critters will help as well (snails and a few hermit crabs)
[B]5. What size heater? [/B]
3-5 watts per gallon. So between 250 to 400 watts. Maybe even two 150 watt heaters.
[B]6. How many pounds of live rock?[/B]
For budgeting purposes plan on about 1lb per gallon. You may use more or less depending on the density of the rock you choose and how you aquascape your aquarium.
[B]7. How many pounds of live sand (if needed)?[/B]
Well sand does make for a nice reef. I would think about a 1Lb per gallon for a decorative sandbed. If you would like a DSB (deep sandbed) with the denitrification benefits you may need 2-3 lbs per gallon.
[B]& last but not least
8. What Kind of lighting and wattage?[/B]
This depends entirely on what you want to keep as far as corals. A combination of metal halide and fluorescent actinics (T5, PC or VHO) seems to always be a good choice. If you are planning on SPS coral, clams and anemone you may want to lean towards 250w MH or higher. If you like mostly soft corals and LPS (acan lords, candy cane, frogspawn) you can likely get away with 150w MH or maybe less. I like 10k or 14k MH lamps with some actinic 03 (420nm) and actinic blue (460nm) T5's or PC's.
Best bet is to make a list of corals you want to keep and find out what their requirements are for light and flow. :)