I am in the process of setting this up on my 75g. I have no holes so have to drill them. Since I am drilling anyway I thought I would go ahead and do 1-1/2" the way I read beans original description is he used 1"because that's what size his hole where already. Now here comes the questions that have probably been asked before many times I just haven't ran across them. If I am using 1-1/2" bulkheads and 90s just like the original design. How far down from the top of the tank do I need to drill my holes? I am going to put a box on the inside. Does that box determine my water level in the display?
Thanks for any help.
Before delving into hole placement, let's look at your flow requirements, and the possible/probable consequences of using 1.5" bulkheads, on a system that will be running under 750 gph. A 1.5" bulkhead will flow low to mid 3000s gph, with a drop of 24" accounting for friction losses. The same "drop" with a 1" bulkhead, will flow around 1500 gph with 1.5" pipe, (as in the original design) double what I would consider reasonable for a 75gallon tank. Most drops will be a bit longer, (higher flow capacity,) but I think you get the idea. The question this raises is why bother with such large bulkheads, when they are simply overkill, and there have been starting issues reported in system running large bulkheads with "low" flow rates... ...bulkhead/pipe size is somewhat of a subjective topic, in that some figure there is no reason to use a pipe size larger than the bulkhead size, though there are parameters that make it rather objective, such as flow rate, length of the drop, friction loss etc., as well as keeping the open channel easy to maintain silence. Since 1" bulkheads, with 1.5" pipe (original design) has such a very wide operating range, I can't see a reason to use 1.5" bulkheads, unless you are targeting 2000 gph +, but I do see reasons not too.
Hole placement (yes you are right it has been covered a thousand times) is pretty objective. The minimum distance is one hole diameter from the edges of the glass, and each other, to the edge of the hole. Allowing for the weir is a bit trickier, and you need plumbing in hand to figure out how much to adjust the holes down, if needed, to get the water level in the "main" area where it needs to be (top of the weir) with around a 1" drop into the overflow (water level.) The water level will end up in the upper half of the downturned elbows, depending on the running adjustment. There is not a formula for it, it is old fashioned tape measure. (I did almost micrometer measurements for 1" and the distance is 2 7/8" down from the bottom lip of the trim inside the the tank, (2 3/4" - 3 1/4",) to hole center. (with 1" elbows; 1.25" elbows will be different.) How critical is it? You have to be at least 1 hole diameter down, you have to clear the trim on the outside of the tank (bulkhead nut) and then the rest is how long is the water fall going to be.