New tank design with ATS in mind

[SantaMonica]

Wish I could help. Only thing I know is 35gph at the slot.

[kcress]

Ah man... 3/4" for an overflow is seriously anemic. Sorry to hear.
What happened to the 1-1/2" Durso(s)?

Maybe I'm confused.

Is this glass or acrylic? Both can be enlarged.
It's easier with the right tools. But you can do a hack job too. (Dremel tool)
You should have two overflows one that is you overflow and one that is the backup.

Ah I see you are talking the return.. Here's the deal: don't sweat a narrow pipe a few inches long. The water just cranks up its speed briefly but the actually head loss is not too bad on a very short piece. Can you run 1" up to the fitting then the 3/4" then back to 1"? If you can try to use fittings that are smooth inside, giving a non-abrupt transition, and you will reduce any head loss even more.

[worley]

Sorry, think you did get mixed up , the 3/4" or 1" pipe issue is the return pipe from the sump pump.
The overflow is still the 2x 1.5" Dursos.
Yeah, the trouble is finding 1" fittings, so to get a 1" to 3/4" adaptor is trouble enough let alone to find one with a smooth transition lol

[worley]

If I wanted to enlarge the hole, How would I enlarge the hole with a Dremel, and which tool should I use?
Also, how safe is it?
I'll post a photo in a sec of the holes/weir plus the rest =)

[kcress]

Yeah lets see a photo! BTW I'm off to bed. now!(3:30AM)

[worley]

Tank without hood, before it was set down:
[attachment=6:2v8qriad]TOM_5254.jpg[/attachment:2v8qriad]

The two holes for the 1.5" bulkhead/durso standpipes on either side with the 30mm hole for the 3/4" feed pipe in the middle:
[attachment=5:2v8qriad]TOM_5256.jpg[/attachment:2v8qriad]

Sump cupboard in the middle under the weir:
[attachment=4:2v8qriad]TOM_5260.jpg[/attachment:2v8qriad]

With huge(ish) sump (36"x22"x18"):
[attachment=3:2v8qriad]TOM_5261.jpg[/attachment:2v8qriad]

Overall tank with the polystyrene under the tank for protection and the nice open hood on:
[attachment=2:2v8qriad]TOM_5263.jpg[/attachment:2v8qriad]

The absolutely tiny Eheim Compact+ 5000 sump pump (look at the size compared to the plug!) and the giant 25/34mm Eheim pipe:
[attachment=1:2v8qriad]TOM_5291.jpg[/attachment:2v8qriad]

The hosetail adaptor that came with the pipe:
[attachment=0:2v8qriad]TOM_5296.jpg[/attachment:2v8qriad]

[worley]

Well, I've bitten the bullet...
I've ordered a 35mm glass diamond hole cutter from a local shop, nice and cheap too, and will be here tomorrow.
I talked to the manufacturer who built the tank, and they told me to just turn the tank upside down, put the diamond cutter over the hole, only press very lightly and keep it constantly wet.
Now, I've cut a 45mm hole in 12mm glass before, and several smaller 6mm holes for the algae scrubber sump's "overflow", and I know fairly well how to do it...
Very slowly! and constant stream of water to keep it cool.

I've also ordered a 25mm bulkhead and all the fittings and piping all over again in 25mm!
I couldn't get a Y adaptor, so I've got what's called a 45 degree T:

The feed will go from the bottom then split into two pipes, and I'm using a 45 elbow to make two parallel pipes that will then come out of the weir and point in different directions.
I may end up getting a valve to control the flow rate coming out of the top so they are both equal.

[kcress]

Thanks for the pics!

Wow that's a lot of holes in a small area.... Drilling that out is a little scary from here.

Go very very slowly. Also you need to make a guide. None of this hold it where you want it BS.

Drill a hole in a piece of wood the size of your hole saw or saw a square in a piece of wood that your hole saw will barely fit in. Clamp or duck tape it in place and have it guide your hole saw.

Alternatively use the 3/4" as the emergency overflow and just use one of the Durso holes for your return.

[worley]

Thanks for the idea with the wood to keep it still, I shall be trying that =)
The glass hole cutter should be at the shop shortly, so I'm going to pick that up later, then I need to put the tank upside down (no small job!) and cut it out.
I've got all the 25mm (0.4mm under 1") pipework, tank connectors, swept bends, 45 degree Ts etc in the post and should hopefully be here tomorrow (but Royal Mail first class delivery has a way of turning up after 2 days rather than 1!)
I had also ordered a load of blue acrylic to go inside the tank and be siliconned on to the back, as well as around the outside the weir with the comb teeth built into the same piece of plastic that the weir "fronting" (not really backing is it?) will be made out of. They're also bending it into one solid piece around the outside of the weir, so no visible joints =).
If everything goes to plan and i have the right plumbing connectors and they all turn up tomorrow I should be able to silicon everything in tomorrow and fill the tank on Sunday or Monday =).
Hopefully I don't have to count this as a water change as I'm enlarging the tank, so all the water from the old tank will make up just under 50% of the water in the new one.

[worley]

The 35mm Diamond Holesaw, with grooves to pull water in:
[attachment=1:1v3b2dp5]TOM_5304.jpg[/attachment:1v3b2dp5]
Tank, upside down, on the floor with towels in the weir to catch the water. (Big thanks to my neighbors Paul and Neil for helping me move the tank again!!)
I've used a jug of water (about 1 litre of water was needed) to keep the glass and drill bit cool to stop cracking.
[attachment=5:1v3b2dp5]TOM_5299.jpg[/attachment:1v3b2dp5]
Lined up the new hole with the guide that came with the holesaw (cut slightly to the left as the original hole wasn't in the middle):
[attachment=4:1v3b2dp5]TOM_5300.jpg[/attachment:1v3b2dp5]
Used some airline with a small knot in to get about 2 drips of water per second close to the holesaw:
[attachment=3:1v3b2dp5]TOM_5301.jpg[/attachment:1v3b2dp5]
Drilling the hole... ZzZzZz...
ZzZzZz... you have to be patient, it took 30 minutes to cut this hole (10mm thick glass), I put virtually no pressure on it at all, just used the weight of the drill, and right at the end even took most of the weight of the drill so it was barely touching so it didn't chip the glass as it came out the other side...
[attachment=0:1v3b2dp5]TOM_5303.jpg[/attachment:1v3b2dp5]
Sucess!! Hardly any chipping, in fact, a better cut than the original :lol:
[attachment=2:1v3b2dp5]TOM_5302.jpg[/attachment:1v3b2dp5]

Next step... The acryllic backing / weir cover / overflow comb (all in one) is turning up tomorrow, so I'll be siliconing that to the back/weir, giving it 24 hours, while doing the plumbing, and then I ought to be able to fill the tank on Sunday!!!
Horraahh!
Only thing I'm lacking now is the lights for the algae scrubber, still not 100% decided on what to go for.