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Wow, sorry to hear about the leak. I'm really surprised you went with sched 40 bulkheads though. When I set my tank up I initially had it drilled for sched 40 but kept breaking the bulkheads (threaded fittings). I eventually "enlarged" my holes for sched 80 bulkheads and I now sleep much easier at night.
Since your holes are "recessed" it wouldn't be so easy to do though without a router and a circle jig.
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