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Are you doing a custom stand, I don't believe a 40 breeder will fit in a standard 75g stand.
Years back I acquired a tank with a glass holes overflow. I always found it louder than advertised. I tried everything, changing flow, using their sound muffling product, was never happy as it was in my living room. I moved and while the tank was dry got the courage to drill a second whole and buy an overflow box and go herbie overflow. I then decided not to test my luck and didn't drill, just kept the return ad is with up and over. Best decision ever made in my years of aquarium. That tank went instantly silent after with everything else remaining the same. These days I've drilled numerous and would drill another for return. If your not comfortable drilling for a return I can assure you that eventually I got over the pipe outside the back of the tank and loved the fact I had a completely silent tank w a backup.
There are really no size restrictions. I think the general recommendation is not to have your full siphon tube less than 3/4. Allot of overflows you'll find people actually use the smaller return pipe as their full siphon and the larger as the backup. (Full siphon can handle more flow than an open tube that had air in it as well). Get a good gate valve-it's worth it! & plumb your return elsewhere. Have you drilled before? Have you made sure not tempered glass?
If it's that tight I wouldn't put another hole in it. You can't put holes too close or you'll create stress cracks/ cause risk for failure. The rule I always use is edge of hole should be at least that same length from any edge/other hole. so if you have 1.25" holes you'd want to keep at least 1.25" of glass in between holes and the edge of aquarium. I'd recommend some type of dril guide. Free handing the drill your first time will just want to walk around on you. Look at brs website they sell drill guides to keep drill steady and straight anc have some good videos on their YouTube.
Similar to the flow thru design I did on my last sump. It's dead quiet. Run a downpipe under the bulkhead with the drain line below the water level. Tune your drain to your return pump output and it will be dead quiet. Skimmer is in 1st section on the platform, I put a rack between the baffles going into the return section for bags of chemipure elite and purigen.
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