Acrylic tank fix help

[Drpritch]

Hi, I've got a 180 acrylic tank that has a chip and crack at the overflow out pipe corner. An old bulkhead was installed by previous owner and upon putting water in, found immediate leak. Re.oved bulkhead and there is a 1/3" chip taken out and 1/2" crack on tank.

Can I fill the chip and reseat new bulkhead or do I need to drill bigger hole and use new bulkhead? Which is better and less likely to ruin tank?

 

[Biglew11]

I think I would cut a small square that's larger than the hole and use some weldon, and glue it over the hole and then drill a hole for the original bulkhead through that new piece. Then your bulkhead fitting will basically sandwich the two layers of acrylic.