Step-by-Step: Drilling Holes in Your Glass Tank for Bulkheads

Hello all, After reading through this entire thread several times; I have convinced myself to give glass dirlling a try.
I have purchased and paid for 2 diamond hole cutters from EBAY user Lau, it was hard not to due to his low cost. Hopefully I will recieve them by next week.

I am going to practice on a 5.5 gal tank I am going to use as a fuge.

I do have a question: How many have drilled their main tank without removing all inhabitants and how did it go? Or is this thinking a bit insane?

If all goes well with the 5.5 I am going to drill the back of my AGA 46 bow with drain and return lines.
 
muelpaul
The 5.5 gal tank has very thin glass, so don't be suprised that you find it hard to drill without breaking a pane. Certainly worth a try, though, and not an expensive loss if a problem does arise. Thicker glass is much easier to drill.
 
I had two 5.5's that I drilled. The problem for me wasn't the actual drilling, which when fine. The problems arose when even the slightest amount of pressure was placed on the glass--both of them cracked. In my opinion a drilled 5.5 is a timebomb.
 
Thanks, swedish steel and NEALH for your advice.

I believe if I place a support brace under the cut it should be fine, Like making a T out of scrap wood and making it just snug and placing it under the hole site.
If I just use the weight of the drill and take my time...hopefully it won't crack:worried:

I recieved an email from Lau, and the hole saws were shipped on the 31st, so hopefully within this week.
 
I know someone else who glued a square of acrylic with a hole cut in it on the other side of the glass before placing the bulkhead, and that supposedly strengthened it enough to keep it from cracking.
 
has anyone drilled 3/4" Sch 80 bulked heads? They are listed as having 1 5/8" outside diameter so I ordered a 42mm hole saw. I just wanted to verify that it is the right size.
 
<a href=showthread.php?s=&postid=9618599#post9618599 target=_blank>Originally posted</a> by NealH
I had two 5.5's that I drilled. The problem for me wasn't the actual drilling, which when fine. The problems arose when even the slightest amount of pressure was placed on the glass--both of them cracked. In my opinion a drilled 5.5 is a timebomb.
Click to expand...

The same thing seems to be happening to the ten gallon tanks I have been trying to drill. Is there a trick to keep the tank from cracking or is it a waste of time.
 
I recently drilled a 10gal twice with a 19.2V cordless drill and didn't have any problems. I just took my time and let the weight of the drill do all the work. Oh yeah, I drilled 45mm holes.
 
I used the same method to drill (using the weight of the drill), any pressure on the plumbing and the glass cracks.
 
What do you mean when you say, "Any pressure on the plumbing and the glass cracks?"

Do you crack the glass when you are tightening up the bulk heads?
 
I think he means that once you have the bulkhead and pvc installed, any sort of torque on the plumbing would cause the glass to break.
 
<a href=showthread.php?s=&postid=9638355#post9638355 target=_blank>Originally posted</a> by NoCarrier
I think he means that once you have the bulkhead and pvc installed, any sort of torque on the plumbing would cause the glass to break.
Click to expand...

yep, thats what I mean. Does this happen to anyone else?
 
<a href=showthread.php?s=&postid=9638745#post9638745 target=_blank>Originally posted</a> by Haffs09
Ahh...I see. Fortunately, that didn't happen to me. Maybe you're overtightening the BH?
Click to expand...

Hi Haffs09, do you happen to have a picture of the placement of the bulk head(s) in the 10gal sump?

On another note; to anyone, where should I place a bulk head for a drain line?
In the middle of the waterline or below? I would like some surface skimming but still want a high flow rate.
 
Muelpaul...I don't have a picture, but I drilled the holes right below the top tank trim, with just enough clearance so the bulkhead nut won't hit the trim. I think I was also about 1.5" from the corner of the tank. The 10gal is serving as a fuge on a 90gal tank. Part of the overflow from the display tank is directed to the fuge. The fuge is on a little stand so that it can overflow into a 20H sump. I hope that helps.
 
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