I have a 150 gal (1/2" glass) that I wanted to add a 2nd return to and needed to drill a couple of holes. The tank was not yet full yet, but the closely LFS store that would drill was 1 hour away and it would have been a major ordeal to un-plumb the rest of the tank and move it So, I decided to purchase a diamond drill bit from Diamond Bit & Tool and take care of the job myself.
Below is the process I used.... your mileage may vary and no warranty granted :wink:
I purchased a cheap drill press off Ebay that I was planning to use, but it ended up due to the size of the drill needed (I had to use a 1/2" drill) and the proximity to the side of the tank I could not use the press. So, I crossed my fingers and went at it freehand.
I picked up a wax toliet ring and placed it around the area I was going to drill. I think poured a little vegtable oil in the ring to serve as a lubricant to keep the bit cool.
The toughest part is getting the hole started. This is where a press would help greatly, but I managed to get the holes started "freehand". I'd recommend some type of template next time... perhaps a piece of 1/8" plywood with a hole cut to the size of the drillbit and then tape it down. This will keep the bit from sliding around while you get it going.
Once I had the hole started, I just kept firm, but not forceful progress on the bit. Added a little veg. oil every minute or two. Probably took me about 5 min per hole or less.... just steady drilling. I was using a Dewalt 1/2" variable speed drill. Ran it somewhere around 1/2 spped. The tank was already on the stand so I had a backer there already but if you don't I'd recommend some type of backer as well.
Anyway, the holes were drilled without event and it saved me the major hasel of pulling the tank out and hauling it 1 hour to the LFS to do the job.....
I've got a slightly used bit now I that I need to get rid of..... (don't remember the specific size right now, but its the size for 1" bulkheads).
Mike