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I'm looking to drill a 40b. I'm very much a novice but it's a 1 1/2inch drain and 1 inch return hole? Can this be done simply by buying parts at lowes, IE, diamond bits, bulk head / adapters, silicon and such or are they specialized enough i would need to find some at a LFS or online? I'm also thinking I can just buy glass, have it cut and affix it together to make an over flow box right?

Side question. If this doesn't turn into a huge mess, I may consider having glass cut to partition a 20L for a new sump under my 72 bf. How much would this shock the system to switch out an already in use sump for a new one?

Thanks
 

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Just order a DIY kit from glass-holes.com. It will include everything you need and by the time you buy what you need from lowes it won't be any more expensive. I wouldn't recommend using glass panes for your overflow as it won't have teeth and is likely fish will jump and wind up in your sump. You should be fine switching sumps, just make sure to transport all lr and equipment over. Lastly make sure that the glass being drilled is not tempered.
 

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I drill press helps too, I use a small section of 3 or 4in. pvc and I set it around the drill bit on the glass. I usually seal where the pvc touches the glass with silicone and I put anti-freeze inside the pvc to keep it cool. I'm sure you know not to put much pressure on the bit at all. I would drill in 10 second incraments on and off as well. Hope this helps!
 
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