anyone here using an external return pump? If you do I need your help.

I will be running T5's. 8 Bulb tek light, closed top. I don't know if there will be heat or not, as it is not up yet. with sump approx 120 gallons water volume.
 
no it isn't drilled. But it is acrylic, so I am pretty sure I can just use a normal hole drilling bit.

That will work, but I've got one piece of advice. First, drill a little at a time. Acrylic melts and it can cause the bit to bind up in the hole if you get it too hot. If it binds as you are getting most of the way through you can get the bit stuck in hard enough that the options are really torquing the bit extra hard to break it loose or trying to yank the bit out and start drilling again.

If you are far enough through that the remainder of the tank wall gives instead of letting your drill go, you can end up with chips on the inside of the tank that may cause your bulkhead to seal very poorly (depending of course, on how you have to orient your bulkhead/o-ring... in any case, chipping is best avoided).

It may not be a horrible idea, if your tank is out of the water and easily turned on its side, to use the same "water dam" technique that people use to drill glass.
 
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