Sump tank size doesn't really matter when using Constant Flood if you have an auto top up valve. If you don't have an auto top up valve then the sump will run dry because of evaporation and transpiration if you're not there to fill it up - this means you have to plant short vacations... not so good. Anyway, that's why I think you should install an auto top up valve.
Basically when you add a grow bed you add the water to fill the grow bed and enough for the pipes but the sump volume doesn't have to change because the level doesn't fluctuate like a siphon type system would.
1. CHOP1

- I forget all these designations, we do occasionally use them but they're not what we started out with on BYAP so I never really got the hang of them - basically you'd be doing what we call CHIFT PIST or Constant Height in Fish Tank, Pump in Sump Tank. The water level always stays the same in the fish tank and there is only one pump at the low spot in the system. The Constant Flood that I mentioned is about having a constant flood level in the grow beds (usually set by a standpipe) and always having the pump running 24/7 - the water movement is what keeps the system aerated - like a river.
2a. I think the only place where overflowing would work is from the fish tank to the top grow bed. You have a choice, you can run the grow beds one after the other (in series) or you can run from the fish tank to both grow beds using separate flows (in parallel). Because the sump is part of grow bed 2 I don't think you can entirely run in parallel because part of your flow will always come from grow bed 1. Your options are basically as follows;
a) Overflow to top grow bed and then from top grow bed to bottom grow bed use a standpipe. This is the running in series option.
b) Overflow to top grow bed and then from top grow bed to bottom grow bed use a standpipe. Have a second flow from the fish tank using a SLO or airlift to overflow to grow bed 2. So part of flow is in parallel and part in series.
c) Overflow from FT using a SLO or airlift to both tanks
There's a chance you'll get too much splashing by overflowing from the fish tank - if this happens you'll probably have to use a SLO. Too much splashing gets lots of water up on the leaves and gives you troubles with plant diseases.
2b. Anyway, you'll need a standpipe or some way to set the water level in grow bed 1. Basically a pipe through the wall between grow bed 1 and grow bed 2 fairly low and then turns upward (low enough withing grow bed 1 that you can get the correct water depth by the upward length of the pipe). It needs a media guard around it.. The upward turn allows you to set the depth.
Hole size depends on the flow rate so I can't say what you need - I don't know what you're going to use for a pump. You should be able to figure it out using tables that provide gravity flow through PVC pipe based on inside diameter - just do a search on the Internet.
Your goal is to turn over the fish tank volume once per hour. Select a pump that can do this at the highest height it will be pumping to (it's good to have a bit extra capacity to aerate the sump as well). Most pumps have a head height table to help you figure this.
3. Oxygenates by water movement and some help from the pump recirculating water in the sump. Take a look at the BYAP Trials thread for a comparison of growth using three different systems over a year.
4. Frequency of cleaning has to do with fish load. I would suggest a light fish load for a system like this, you'll still get good plant growth and then it can go for years without cleaning.