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Those are lots of what if's John. I've never come across such a unique situation such as this....In all honesty I just don't know in regards to those scenarios. James could probably answer that better than I (regarding closed loop etc...). Depending on hole placement it may jeopardize the integrity, that is something during a design phase I would discuss with the manufacture...of course with that said the damage would not have been isolated to one spot. This is all speculation of course....
I am positive that no manufacture worth anything would risk their rep to build a tank with those dims and that thickness of material.
When I was designing that 540 (96" x 36" x 36") we talked about I was cleared hot with manufacture to do 3/4 sides only but the length would have to be 1" or there would be no warranty and from a liability stand point I won't sell anything that the manufacture won't stand behind.
Jesse
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