HDPE cuts just like any other plastic. Your radial saw should be fine.
Trace out the overflow and use a drill to make holes on the inside (area you're cutting out to make room for the overflow), so the jigsaw can make the turn at the corner. You'll be fine. Dont forget to silicone the cutting board down to the bottom of the tank or detritus will get underneath it and defeat the purpose of going BB.
Nope. It floats.
Your tank is already running?
If so, then dont worry about it.
Lots of folks are running BB tanks just fine without starboard/cutting board bottoms.
Here's my 40 Gallon Breeder tank. I use about 40 lbs. of my 50 lbs. of rock and put it together like a puzzle. I used fiberglass rods and DryLok Fast plug to "glue" them together.
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There are four separate standalone sections. Each have the bottoms cut flat and rest right on the glass. None of them can tip over and the two back large pieces only touch each other where they meet though they look like one solid structure. There is a lot of space all around them and in between with lots of shelves. It is pretty minimalistic IMO.
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Will be putting the sand in today while I wait for my RODI unit to make some pure water.
Here are some other angles...
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The idea is to only work with one pilar on a PVC Foam board. Materials used Fiji rock dead, PVC Foam, Tie-rips, Epoxy, Speedglue and Keramikkleber.
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@basjacobs
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Almost done...