Best way to increase the diameter on an overflow for a bulkhead?

[infin]

I have 2 overflows that are built in on my 200 gallon acrylic tank.

I had standard bulkheads but one cracked so i bought some heavy duty ones.

The heavy duty ones are about 1/4" wider in diameter and will not fit into the holes on the tank.

What is my best course of action to make these holes larger?

the acrylic is 1/2" thick.

tank is currently all drained out.

 

[Squirtle919]

I BELIEVE being acrylic you can just drill the holes out with a hole saw for wood. I could be wrong so best to wait for someone else to verify this but I am 90% sure thats how acrylic is drilled so you wont need any diamond bits etc making it quite simple.

 

[DB junkie]

I use a pneumatic die grinder with a carbide bit in it. The bits are for metal but eat up acrylic with ease. Have used them on acrylic up to an inch thick.

IF using a hole saw I use water with it, same with a jig saw/sawzall. All would work as well......

 

[brich999]

The issue with using a hole saw is you wont get the middle pilot hole to bite which will make it difficult to hold in place making a good clean hole. Drilling acrylic isnt difficult at all but your case may be tricky because you really need that guide to hold it straight

 

[DB junkie]

I actually use a home made jig with the hole saws. Made from a small piece of plastic with rollerblade bearings and spacers. Suction cups on the bottom.

No pilot needed.

Definitely makes drilling glass easier, works with acrylic too......

 

[brich999]

I actually use a home made jig with the hole saws. Made from a small piece of plastic with rollerblade bearings and spacers. Suction cups on the bottom.

No pilot needed.

Definitely makes drilling glass easier, works with acrylic too......

Well isnt that nifty. Learned my new trick for today.

 

[DB junkie]

Well isnt that nifty. Learned my new trick for today.

Saw them for sale on glass-holes.com, had the stuff laying around here so thought why not give it a try? The things worked flawlessly.... lol Bearings have even held up to the water used when drilling......

 

[Squirtle919]

Nice idea junkie, might need to try that one!

I never drill acrylic but with glass I start on the angle then straighten it up can be a bit of a pain at times, your little jig would make life so simple! :d

 

[Steveo McNello]

Sand it out with a dremel tool with a sanding bit. Just slowly ride the circumference until its wide enough for the new bulkhead.


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[Drstrangelove]

I actually use a home made jig with the hole saws. Made from a small piece of plastic with rollerblade bearings and spacers. Suction cups on the bottom.

No pilot needed.

Definitely makes drilling glass easier, works with acrylic too......

People like you drive me nuts since I am so incompetent with materials and mechanics.