Never heard of a durso "breaking in" before.
This is why I went with a dual drain setup. Obviously it's too late for that, I would look into a new sump. Multiple chambers will keep the bubbles from reaching ur return pump.
I have the same issue on my 180 and my frag tank and my chicks tank before I did a herbie drain. Single durso's are like impossible to get the air from not going to the sump. One thing I did was add a gate valve to the drain. Helped stop a lot of bubbles.
Hot Dogs are GOOD!