In order for my idea for the overflow to work, I had to drill the tank. I ordered 1/2" bulkheads from
http://www.marinedepot.com since they ship from anaheim and I recieved them the next day. The problem was they sent me 3/4" and didn't have any 1/2" in stock.......
The only diamond bit we had was 1 3/8" and 3/4" require a 1 1/2" hole. We checked with some calipers and found that the bit is just big enough for the bulkheads so I went ahead with the drilling.
Now neither me or my dad have ever drilled glass, and I wasn't about to test my skills on a 100$ tank. So I went to a local glass shop to ask if they could drill it. Aparently the drill press thye have was too big to fit in my tank, so they couldn't help me. He did however give me a nice size piece of scrap glass to practice on for free
In the picture you can see the guide I have set up for the bit. This is a must have since it will walk all over the glass if you don't have something to prevent it from moving. I used a 1 3/8" wood hole saw and drilled the hole 1 1/2" from each corner (This would help me place the hole in the tank and prevent from getting too close to the edges). It also held water decently well.
Once you get a nice groove started, you can remove the template and keep drilling. I never had a problem with water moving away from the bit so I didn't bother setting up a barrier for it. The bit was always nice and cool to. I did constantly spray with water though and would periodically stop to wipe away all the bits of glass.
First try we did it wil no cracking or problems. It does take a while (Like 10-15 minutes for 1/4" glass) but It's better to go slow. You can also see the bulkhead fits perfect in a 1 3/8" hole
*edit* Yes the door is done already.....Well it's assembled. It's actually waiting in the sun right now getting ready for primer along with the canopy :P
