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So in the process of my leak test, when pump is on the res is about 3/4 full, when off its completely full. Does that just mean there's plenty of air still in it? I don't add more water when it's on and 3/4 right?

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You can add as much as you want to fill the res. I wouldn't top off though, there's still air in there. Once it stops dropping in water level (not when you turn the pump on when it's off) top off while the pump is off.

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There will always be some air in your loop, some loops need months to get all the air out. 3/4 full is okay, you dont want to overfill it, else bad things will happen (never saw that though, if you are mad enough to try that, post some pics! :D) What may also help you, use a small tiny drop of soap, it will help bleed out your system :D

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