one more thing ...
No glass shop or Sea Star will garantee to not break your tank in the process of drilling it. 40 gallon tanks are cheap ..... my advice would be to buy a new one drilled. As for the return line ....... like Brad mine are drilled in the bottom for the overflow and I return over the top of the tank. ( I have 3 like this )If you decide you want to have the return hole in the bottom, your going to have to install a check valve inline to stop draining your tank if the power goes off.
just my 2 cents worth ....
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