Leaking bulkead solution?
 

Alright, so I'm still somewhat of a novice here.. but I tried something most people wouldnt and thats building my own custom sized aquarium.

Learned a lot since I started the project and I finally filled the thing up the other night and I fear there may have been a slight but crucial mistake during construction.

One of the bulkheads leaked a bit. I'm not sure if it was how I had the thing tightened down or if the hole drilled may be a bit too big. If I push the bulkhead all the way to one side as far as possible you CAN slightly see the hole that has been drilled. Also, underneith the plywood isn't exactly flat its all chipped.. but I dont see how that would be a problem

That being said.. IF this is the issue how can I fix short of draining the whole 100G display tank and disassembling and getting a whole new peice of glass..

I KNOW I cant just silicone it as it wont adhere properly to the bulkhead.

Here's what I'm thinking:
If I can cut a small square of some type of material (which the silicone WILL adhere to) larger than the hole and then drill out the proper sized hole in that.. then silicone the tits out of that against the glass.. then install the bulkhead normally over that peice.

Thoughts?

if you are looking for a bit larger diameter bulk head with a thicker gasket.
You may want to look at the schedule 80 bulk heads at bulk reef supply.

Is it possible to drill a bigger hole and just use a larger bulkhead? That would be the easiest and make sure to have the proper hole for the new bulkhead

not sure if changing the bulkead size is going to work they're pretty standard arent they?

i really dont think i can get a drill in there at this point and not only that i'd also have to drill through the tile and the plywood then.. its not gonna happen haha

The schedule 80 bulk heads are a couple of mm larger diameter then the abs ones commonly used & have a larger thicker gasket mite be what your looking for ?
http://www.bulkreefsupply.com/bulkhe...-thread-2.html

they look great but.. i need extra long thread fittings because i'm going through 3/4 plywood as well as 3/8 tile and 1/2 glass lol

Unless you can stop the water it will interfere with curing. U could try using underwater silicone inside the tank around the outer edge. Then water pressure would push the silicone into the cracks rather than out.

Since you said the tank is plywood I would really look the hole over. If it's leakng around the rubber gasket then the wood is absorbing the saltwater and weakening as we speak.

Are you tightening the bulkhead nut onto the plywood?

Sch80 bulkheads do wonders, it's amazing so many people don't use them. Corse threads and thicker gaskets means a much tighter seal and they can take more pipe load. Try and find one that fits your hole better, there are many different brands that require different hole sizes. If you measure your hole myself or others can point you in the right direction. Thread depth shouldn't matter, the nut should butt up to the glass and you need a clearance hole large enough in you stand to clear the nut and allow access for tightening.