For my tiny 29-gallon Nano Cube, I drilled my bulkhead holes. No problems. However, measurement-wise, the bulkheads sit kind of low for my tank, following the specs used by BeanAnimal: the horizontal center for the 1" bulkheads is 4.25" from the top of the trim. Hence, I am trying to shorten up the down-turn of the street elbows in the overflow box--otherwise the box will be unnecessarily deep: 6 inches! That's too deep for such a small tank that will host a live reef. My goal was to have the overflow box be no deeper than 5 inches. I can cut off 3/4" from the down-turn of the street elbows, to give me 1/4" clearance for the bottom of the overflow box. Under such a scenario, the overflow box would be somewhat deep, 5-1/4", as opposed to my desired 5". However, that would be better than 6" deep.
Here's the question though: under this method, only the top of the street elbow would sweep downward, the bottom of the street elbow would be level with the bottom of the horizontal pipe connected to the "down turn." While the incoming water would still "feed" into the elbow from a vertical position--i.e., from a downturn angle (not a horizontal opening), it would be a very short "downturn." Would this shortness work, provided that the inlet is parallel to the water (i.e., the inlet is in a vertical position), not perpendicular to the water (i.e., the inlet is not in a horizontal position)?
If this won't work, what is the shortest "stubbing" of the downturn I can have? Here are some pictures of what I propose. Thanks for your reply.
In this first image, the shortest street elbow is on the left. The middle elbow would be cut to the same, height. The left elbow would be the siphon standpipe. The center would be the open channel standpipe. The right elbow could be kept at that same height, if appropriate, or it could be cut down to the same size as the left and middle elbows. Notice the height differential between the stock elbow (the middle channel) and the short elbow (the left channel.)
More angles.
Here's how short it would be:
http://i883.photobucket.com/albums/ac35/SkyReef/115.jpg
http://i883.photobucket.com/albums/ac35/SkyReef/116.jpg
http://i883.photobucket.com/albums/ac35/SkyReef/117.jpg
Compare how much would be cropped: