Unfortunately egg crate is not going to work. At least put a layer of roughed-up plastic canvas over it. And use proper wattage based on feeding:
Nutrients "in" (feeding) must equal nutrients "out" (scrubber growth), no matter how many gallons you have. So...
An example VERTICAL waterfall screen size is 3 X 4 inches = 12 square inches of screen (7.5 X 10 cm = 75 sq cm) with a total of 12 real watts (not equivalent) of fluorescent light for 18 hours a day. If all 12 watts are on one side, it is a 1-sided screen. If 6 watts are on each side, it is a 2-sided screen, but the total is still 12 watts for 18 hours a day. This screen size and wattage should be able to handle the following amounts of daily feeding:
1 frozen cube per day (2-sided screen), or
1/2 frozen cube per day (1-sided screen), or
10 pinches of flake food per day (2-sided screen), or
5 pinches of flake food per day (1-sided screen), or
10 square inches (60 sq cm) of nori per day (2-sided screen), or
5 square inches (30 sq cm) of nori per day (1-sided screen), or
0.1 dry ounce (2.8 grams) of pellet food per day (2-sided screen), or
0.05 dry ounce (1.4 grams) of pellet food per day (1-sided screen)
High-wattage technique: Double the wattage, and cut the hours in half (to 9 per day). This will get brown screens to grow green much faster. Thus the example above would be 12 watts on each side, for a total of 24 watts, but for only 9 hours per day. If growth starts to turn YELLOW, then increase the flow, or add iron, or reduce the number of hours. And since the bulbs are operating for 9 hours instead of 18, they will last 6 months instead of 3 months.
Clean algae off of screen every 7 to 14 days, so that you can see the white screen material.