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2.

 

Now locate the drilling template where you have determined you need to drill the hole(s). Note that the 
template is the same outline as the actual Front Overflow Box. Make sure the template is in the CORRECT 
UP orientation. Manually align the template on the inside of the aquarium and MARK the holes with your 
marker.  
 

3.

 

After marking the holes locations, use the Rear Overflow Box and align it to the circles you just drew on the 
aquarium. If the rear box aligns with the holes and is not hitting the rear plastic trim on trimmed tanks, then 
you are ready to mount the template and drill. You can use duct tape to mount the template, although we do 
recommend using spring clamps to hold it in place. DO NOT use screw type clamps, these can cause too much 
localized stress and crack your glass!  

 
 

4.

 

Make sure to protect the opposite panel and position a bucket or reservoir to catch the plug when it drills 
through. Also if placing a bucket on the glass, protect the glass from the bucket by placing a piece of paper 
towel and/or clean cardboard so that the bucket doesn’t scratch the tank.  

 

5.

 

Ideally you will use a cordless drill with an adjustable clutch that can be set very light. This will prevent extra 
force on the glass should you bind the bit during drilling. It is now time to start drilling!! Pour some regular 
old water in the template hole to cool and lubricate the holesaw, you will want to keep the bit wet through the 
whole drilling process. The provided template will keep your holesaw in place. Water will channel thru the 
template. This is normal.  

 

6.

 

After drilling for a bit you should be able to remove the hole saw from the template and see a groove starting 
in the glass. Once you see this groove you may want to remove the drilling template; it has served its purpose. 
Be sure to start both holes before removing the template. 

 

7.

 

Remember to keep the hole-saw wet through the process for cooling and lubrication. As you get near to the 
end of drilling the hole you will see the water start to leak through, this is the sign that you are close. At this 
point you will want to use very light pressure and patience to minimize chip out on the opposite side. 
However, some chips is normal and likely so don’t worry about them as the gasket will cover and seal them. 

 

8.

 

Once you drill both holes, clean up the drilling mess and dry the aquarium and proceed to install the boxes. 

 

9.

 

Remove the nuts from the bulkheads. Place 1 gasket on each of the bulkheads on the front overflow box and 
mount the Synergy Reef Overflow by inserting the bulkheads through the holes you just drilled from the 
inside of the tank, this gasket will be between the front overflow box and the tank. Get another gasket and put 
it over each bulkhead on the outside of the tank. This gasket will be between the tank and the external box. 
Insert the external box through the bulkheads and secure it in place with the 2 nuts your removed earlier and 
hand tighten. Over tightening the bulkheads can cause the gaskets to leak. See figure A.1 on next page. 

 

10.

 

Your overflow is now ready to plumb any way you choose. Enjoy!  

 
More information can be found on our website 

www.synergyreef.com

 

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