Talked to a friend tonight who called to get some filtration plumbing advice for his 620 Titan. I showed him something I had just found today on Flexpvc.com.
http://flexpvc.com/cart/agora.cgi?product=Barb-Manifolds. It should solve his problem and is only $7.45 plus shipping.
I asked if he knew anyone who could chop the tank for me and he's going to check with two guys he knows to see how much.
I'm done trying to figure out how to make this work. I'm sure the Permadri will work if sprayed on with the special equipment or on a brushed/rolled on a perfectly constructed tank.
After talking with my friend, I'm ready to get to what I like doing; building filtration and raising fish!