thinking I will keep most of the current rock just worried about stirring up sand n such.
any one ever use concrete in aquarium ? , was thinking of doing closed loop in rock-work
It can be done. I rescaped my 17 gallon multiple times during water changes and everything lived. It was cloudy for a bit though. On my 40, i wasn't really aquascaping but had to remove all of my rock and water so I could move the tank and dry out the few gallons that spilled out due to a dirty filter sock overflow. I put everything back without doing a water change and everything was fine. I kept my rocks wet though by keeping them in the buckets of tank water. I also dropped a heater in. It took me about 6 hours to do everything with no losses. I am considering rescaping the 40 because I want a different look. Biggest pain though is not breaking corals and being able to remove corals from rocks that you want to move to different rocks. I would think a table saw or dremel tool might help though. the key is to keep your stuff wet. If you leave the rocks out too long, die off can happen and mess with the tank. You would probably go through a mini cycle.
The only problem I ever had redoing rockwork was when a big rock uexpectedly shifted and killed my blue jaw trigger fish that was hiding below. Kind of a huge bummer. No cycling though.