Thanks for all of the replies! I am just going to use some sch40 bulkheads for sure.
I went with the schedule80 because most of the plumbing is visible, I also just really like the look/quality of the sch80. It has turned out to be a pain though.
The new holes were only going to be 5mm larger so trying to drill 2.55mm off each side seems awful sketchy.
I have really got to try and get some pics of this thing up here
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