I was actually thinking this exact same thing but I ended up picking up a nice unused glass hole overflow from a member here and he gave me a amazingly reasonable price too.
Unfortunately the bulkheads don't quite match up so I'll have to make my own external overflow box since these overflows can't really be set to run herbie or anything.
Anthony offered to help tomorrow at the BBQ to drill the holes for a small fee but since the kit came with a drill bit I might attempt to tackle this myself and save a couple bucks too.
So I've been told that it's ideal to drill holes with a drill that has a clutch but I only have a drill connecting straight to the wall with no clutch that I'm aware of. Is there high risk to use what I have or should I borrow tools that are better?
Also, do the diamond coated drill bits work well on acrylic/polycarbonate? I have a 1" hole saw but these bulkheads on the overflow are 1.5" so I was thinking of just using the drill bits after I cut glass to cut the holes in the external box too.

http://imgur.com/BQRAeRt.jpg

http://imgur.com/GDRg3nC.jpg

My inline TDS meter actually arrived today (amazon prime is simply the best), but I might actually just grab a handheld one down the line as they cost almost nothing and you're right, it does sound convenient to have one you can test any water with.

Get Anthony to do it. If you had an old tank sitting around you could practise, but if he's willing to do it, then I'd take him up on it. He's also knowledgeable enough that he should he able to spot if it's tempered.

You can't use diamond bits on any plastics - they will heat up and melt the plastic which then sticks on the bit.

OK I'll take it to Anthony's tomorrow.
Ah dang now I need to find a 1.5" hole saw Haha

Anthony doesn't have one? Is there a Princess Auto where you live? I get them there...they're only $15.

Cool build so far! I love how you keep changing your mind, to try and get the best possible end result. I am notorious for this, it drives my wife nuts. I call it being adaptative and dynamic :wink: Tagging along.

I'll ask him today when I'm over at his place.

I know exactly what you mean! I'll tackle a project with the mindset of keeping it simple and low budget, but as I start to get going and do more research I'll be like "well I mean I already started so I might as well make it the best I can" and before I know it I'll have gone through like 5 revisions. I like how you call it, I'll use that term in my future resumes haha

Had a really fun time at Anthony's BBQ this weekend and finally got my tank drilled thanks to Anthony.

His tanks were beautiful!

http://imgur.com/MZHkGtb.jpg

Finally drilled the tank! Anthony got both holes done in less than 5 minutes I think, it was quite impressive.

http://imgur.com/NWIXlGj.jpg

Now I just need to find some help to get an external box built for the overflow. Anyone good with working with acrylic/polycarbonate that can help out?

http://imgur.com/FHArR8F.jpg

Nice. That Anthony is good people!

Why aren't you doing it in glass? You're practically an expert now!

I might actually have just enough scrap glass left over to do this. I'd have to take it back to Anthony to get some 1" holes drilled
I would have to strip the paint off the section of the back too in order to silicone the box on and because I don't know how the paint would affect the livestock

Looks good! Make the outside box the same size as the inside box so you can't see into it from inside the tank. :)