Well ive sorted it, i just simply sanded down the thread on the tank connector, so now im gunna just run 3/4 inch (22mm internal size). To make extra precautions i will have a accesable roof on my overflowbox and make the water slits very narrow, and that should solve the problem of snails entering and any algea growing indside.
This sould be ok tbh i was contemplating drilling 2 but there two main factors though:
1: ill be running total of 1 1/2" which seems slight over kill on a 140lt cube with a max of 5x turnover and plus the return pipe size is gunna be 1/2" its gunna have to be a higher turn over pump or else it keep draining--- refilling slowly--- draining---- refilling slowly etc etc
2: Ive designed the tank so if either fails no overflow will form.
But one thing is it normal to get the odd chip when the cut out falls out?