Besides the above, I made lots of progress today. I finally got up the nerve to drill holes in the front of the 120g BG.
I was having a really hard time thinking how I was going to measure and cut the holes in the background to line up perfectly with the returns. There is a bulkhead fitting, three 90 degree elbows and the return pipe to get exactly right. Here is how I did it. I am not a very crafty guy so I am rather proud of how I pulled it off. I drilled the backgroun first and matched the plumbing to the holes.
I used the larger bit I posted above on another test piece and it fit snug. Just what I wanted. No sanding at all.
When I laid out the plumbing, I cut everything too tall intentionally. This was so I got my horizontal spacing measurements exactly where I wanted them and to cut the bottom of the BG to fit over the bulkhead fittings/elbows.
I marked where I wanted the horizontal with a sharpie and the measure down 2.5" down and marked the vertical cross section.
I pulled the BG out and drilled a pilot hole through the front. (to the right of the drill bit in this pic)
I drilled hole through the back towards the front. The front is uneven (3D) and my bit would bounce all over the place. Good thing I found that out on a practice piece. Drilling from the back made the front hole pretty clean actually. The material on the inside is much softer than the outside.
This is the hole from the front. Yes those are DC slippers. Real men wear slippers...
The Loc-Line is a perfect fit. I didn't have to sand the holes or anything. Stoked how it came out.
I put the BG back in and this is the only plumbing you will see from inside the tank. I bought the Loc-Line and decided to have it in the tank so I can move the flow around without powerheads. I actually like how it looks.
The hole on the right side was allot harder to do. I drilled it from the back too but this spot was a "branch" and not as easy to drill. The backside was not flat either so hgetting it straight was a little more tricky.
From the front it look OK. I did have to sand and touch up this hole. I forgot to take a pic when I was done though.
More pics of cutting and finishing the plumbing in a sec.