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Yes I too was a
little taken aback when someone put the notion into my
head. Drilling glass is absurd and only for the pros not for us DIYers.
I am here to testify that not only is it feasible but entirely safe.
the 10 years or so being in the hobby I have done just about everything
there is to do to a tank except drilling one. I have even cut a tank
down on one side (just check my basement system) but popping a hole in
one sounded risky. I have now drilled about a dozen or so holes in
tanks of varying size. While I am no expert I am able to report it is
entirely safe if done properly.
Safety
Precautions:
Please wear
safety eyewear at all times while performing this task.
Latex gloves are also a good idea. There will be sand and tiny glass
shards flying out of your hole so be careful. The last thing we need to
do is injure ourselves doing what we love. I implore you to be careful
this stuff could hurt you. This also means adult supervision for some
and we know who we are.
The
tools:
One Pair of
Safety glasses
One pair of
latex gloves
Dremel bit #
7103 (see figure 1 bellow)
Dremel bit #
7134 or 7144 (see figure 1 below)
One Dremel tool
or equivalent
One Spray Bottle
(full of cool water)
One Sharpie
Marker
One Bulkhead
Fitting (size depending on application)
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Figure 1. diamond encrusted
dremel bits
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The
Process:
I will be
describing the 2 person process which I demonstrated at the
meeting. If you can come up with a fool proof way of delivering the
proper amount of cooling water with out a spray bottle and a partner,
please email me.
Begin by marking
the glass. Take the outside nut off the bulkhead
fitting(see figure 2). This will be the template
for marking your hole. You will be
making your marks inside the tank because water will wash off your
marks. I find taping the nut in the position you want the hole helpful
in marking. Now trace the inside of the nut trying to follow the
outermost line of the inner part of the nut. Marking the hole this way
insures a hole big enough to accommodate the thread of the fitting.
Remove the nut from inside the tank. You are ready to begin drilling.
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Figure 2. notice the bulkhead
taped to the inside of the tank
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Now you must
wear your protective gear before continuing any further.
Have your partner spray a puddle on your mark. Using the #7103 bit make
a hole on your line.
Orbiting the bit
will give you a wider hole and allow you to slip the
next bit through the glass more easily. Start with your bit on an angle
and slowly turn up the Dremel until it is upright.Your partner
should
be continually shooting water on the bit and
the hole during all of
this process. If you are seeing dry sand out of your bit you aren’t
using enough water. The byproduct of your drilling should be watery
sand. Continue to drill through the glass orbiting as you go. Use even
firm pressure but do not force the bit through the glass. When you have
popped the hole through carefully remove the bit from the hole.
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Figure 3. start the drilling
process on an angle.
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You will now
have to change bits to either the #7134 or the
#7144. These bits are for routing out the rest of the hole.
Place
the bit back through the glass. Have your partner resume the water
cooling and begin. You will be routing out your line, that is to say,
you need to be right on your line or outside it to insure a good fit
and avoid any after cutting adjustments. Be sure you are using enough
water to keep the glass wet and water on the bit. The routing will take
some up and down strokes of the bit. You need to be careful here
because the bit can easily slip out of your hole, this will not cause
serious damage to your glass but the marks from the bit will be
visible. Using firm pressure again rout out the line all the way around
the circle. You need to be diligent with cooling the bit with water,
heat is our enemy here. When arriving at the end of your cut try not to
rush through to the other side. There will be much temptation to finish
in a hurry but try not to be in a hurry. Carefully finish the cut with
slow even strokes with the bit. The glass round will fall out so be
careful to either catch it or have a towel under it to cushion the
fall.
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Figure 4. cutting out the
circle. notice the water.
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When the hole is
done try the bulkhead for size. If you have difficulty
sliding the fitting in easily you will need to make adjustments.
Adjustments are easily made my using the same bit you used in routing
out your hole. Being careful to continue cooling the bit and the work
go back over your hole looking for non rounded portions to round out
the hole. Stop occasionally to try the fitting again and look for
problem areas. After correcting the problems try the fitting it should
glide right into your hole.
As a foot note
to all of this, I have drilled tanks of varying size and
have found the drilling thicker glass is easier than thinner. Therefore
it is easier to drill a 120 gallon tank as opposed to a 10 gallon tank.
Thinner glass is easier to come out of with the bit while routing our
hole and is also more prone to breakage. I haven’t broken a tank yet
and if you follow these directions you shouldn’t either.
I hope that this
article answers some of your questions about drilling
a hole in glass. Remember to keep your work cool with water and
yourself safe with glasses and gloves. Also be aware that over
tightening a bulkhead fitting can and will crack glass. I suggest going
just a hair over hand tight for all bulkheads. Please feel free to
contact me via this website if you have any further questions.
Jim Blodis
SV-Sea President
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