What Size Bulkhead/Plumbing?

Yes... basically with this tool I will be shaving the hole to enlarge it?

I like this idea as I really want to use sched 80 bulkheads. They might be overkill - but they are heavy duty & no worrying about cracking one.
Yes, that's what it's for. If your drill has variable speed, then use the lowest setting for PVC. It can't be used on acrylic. Click on specifications tab at Lowe's. It's available locally at Lowe's but not available at HD locally (online order only).

Before making a modification, make sure the bottom of your overflow box is wide enough for a sch 80 bulkhead that you plan to buy.
 
As you may already know, Lowes.com can tell you whether some locations near your home have the bit in stock or not.

BTW, I think it's hard to find sch 80 bulkheads locally. Maybe LFS has them. I used to go to a plumbing distributor to buy stuffs (sch 80) near my home. They didn't mind. Maybe you will be lucky to find one near your home. Lowes and HD don't carry sch 80 in stores at all.

If you want good ones, http://www.bulkreefsupply.com/bulkhead-schedule-80-slip-x-thread-slip-on-the-flange-head-side-1-3c30bc3ec05967d33995f258b184fabb.html
Shop around to compare prices if you want. Don't need to glue standpipes into slip flanges. On other end with nut (on outside of the overflow box), you decide slip or thread (thread is good for removal, reused [after gasket replacement if needed] or resale). Good luck!
 
Wow is all I can say.

Just buy the schedule 40. Why spend hours with significant risk to your tank just to spend more money on parts that are way above the required grade???
 
Wow?! If that's the outlook you have then why buy a dimmable sunpower when the non dimmable will work just fine? Why buy an automatic water changer when you can do it yourself in 5-10 minutes? Why buy led when MH is more proven? Why go for (2) vortech when (2) Tunze are fine?

This hobby is full of redundancy & over done equipment & methods. And you're blown away by $20 extra of pvc? lol
 
There is no risk to buying a dimmable ballast, there is when you drill out an existing hole with a cheap dremmel tool. If the bulkhead was big enough no issues with choosing schedule 80. No reason at all to justify redrilling a tank.
 
The reason to justify is to use sched 80 because I like sched 80 dark gray pvc. The fact it's my tank justifies my reason.

There is little risk to damage if you're smart & careful.
 
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