@spankna are you using this pump "
SEAFLO SFDP1-012-035-21, 4.3lpm/1.2gpm, 12V 1.7a" or this pump "
SEAFLO SFDP1-007-020-21 2.6lpm/0.7gpm, 12V 1.2a"?
I am using both pumps in two different systems. The 0.7gpm as a direct replacement for either pump and the 1.2gpm as an experimental replacement for the drain pump. I had orginally ordered the 1.2 gpm pump to replace a slow drain pump and you'll have no issues with that. I can't say that I ever measured how long it took to overflow when using the larger size pumps in both locations, I'll have to watch the next time to see if they overflow and how long it takes.
You might check to make sure the hole between the step filter sections is clean and unobstructed. Also, I would be interested to see what happens when one brews using the faster pump vs the slower pump, when it is used in the wort pump location. I would think drainage through the grain bed would be the same, even if you had more overflow. That's how the system was designed and I am not sure that the speed at which overflow begins, would be a problem.
It's such a small enclosed system that even a faster pump shouldn't cause an issue in heat transfer in the RIMS either. When I took my RIMS unit apart the element was caked black with wort (another reason to deep clean using PBW) and maybe the speed had something to do with that. It's definitely still an experiment though, so use those faster pumps with that in mind, if using in the wort pump location.
What do you mean by this "I need to take a better look at the boards prior to the old pumps but I believe they were some sort of speed regulator to slow the pumps."??