I have drilled at least 10 holes in glass tanks... I have used the Dremel bits and hole saws. Water is essential.
Some folks use Plumber's Putty in a circle around where the hole will be to make a little "pond". I use a spray bottle and let it drain off.
I did find large diamond hole saws on-line. I'll see what the largest one I have is, but I think it is around 2.5 inches or so. It was a Harbor Freight or one of those companies I bought them from. Pretty cheap, actually.
What I have often done is use a smaller hole saw with a diamond "drum" bit, basically a cylinder about 1 inch in diameter covered with grit in a standard drill, and just grind the hole out to the required size.
The Dremel thing never worked that well for me... No real problems, but it was always very slow, and I had trouble keeping the hole "round". I did have it chip out once, but was able to grind that crack out within the limits of the bulkhead I was using. Plus, my electric drill is battery operated, while my Dremel is not.
You probably know, but be sure your tank is not tempered glass. I had two nearly identical (so I thought) 55's I drilled... one was tempered, one was not. The Tempered one I drilled last. Really impressive to see the entire side of a 55 vaporize. Oh, and that reminds me: be sure to use safety glasses and perhaps gloves.
-Mike
MattTVI;30817 wrote: George,
The dremel tile cutting bit, does it require the glass to be wet?