I was wanting to weld up the sides and divider but I still dont know how much space to allow for the under current section. I'm going to make everything adjustable but would like to know a base line to start from.
Depends on what you are using for riffles underneath. If it's just ½" expanded then 5/8" to 3/4" over the top with a 3/16 punch plate will work fine. If you go ¼" then no more than 1". If you are going to make riffles, it's not needed, expanded works fine. I have movies on how to do it completely on my youtube channel. Why are you making a new box? at 15" the old one will be perfect for an over/ under & it's just not cost effective with that flotation. The pointed end of the floats go up stream if there is a pointed end. If not and you are building a larger box, you will need to add flotation and build a new frame. It sounds like you have a clue & a new frame is simple.
On a side note, specs is right. But the Keene 3 stage still sucks when compared to their good old full length over/ under. Proline has a better dredge all of the way around, the Keene box is a joke designed to make it look high tech for high profits. They were better off by far before they sold out what they had to try and copy the proline powerjet coupling. It was a shame to watch that well respected company start walking down that road when they had the best coupling on the market with their clamp over hose coupling. With a little duct tape it sealed perfectly and lasted forever. Now if you tear the hose, down you go