Oh ok, I might have misread it. Yeah, I got 3/4" because that is thickness of the bottom panel. So i was just using the same dimensions.#40 is actually the thickest acrylic glue offered. It can fill gaps up to 1/4” easily and when butt joining or seaming sheets together you actually want a gap to fill. Its stronger when theres a gap rather than pushed together to tightly like with clamps y i recommend using masking tape to hold it in place after you glue…
A 3/4” thick patch is super overkill so u should be more than fine there.
I think u might be reading about/ thinking of the solvent #4 or #3. That is a very thin water like substance that evaporates and needs some practice to work with properly. It needs weighted or clamped down with a certain amt of pressure to achieve a bubble free seam. You need a needle type applicator to shoot it into seams or underneath patches also. Its an option tho and is very strong when done properly. Try and research the “pin method” with solvent.
#40 is a 2 part epoxy that is basically liquid acrylic. You measure it out on a gram scale or by ml and have around 15min to work with it. Its a thick syrup consistency and can be poured onto the surface right out of ur mixing cups. It does not stay put tho. It runs/self levels and you have to kinda trap it in place with tape or gravity. If u choose #40 you could even just tape the bottom of ur holes and fill them up with the glue flush and not even need a patch.
That is an interesting solution to the bulkhead holes. I might try something similar to that but instead of filing the entire hole with #40, I might just cut the spare acrylic panel into circles (slightly smaller than the bulkhead holes) then insert it into each hole, then use the #40 around it to fill the gap.