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The "flake" probably won't be an issue. Does the bulkhead gasket cover it? if so no problem. If not reverse the bulkhead so the gasket is on the good side and it will be fine.
Honestly I can't imagine 2 hours to drill a hole, IME it takes maybe 1/2 hour setup to cleanup.... I've never tried tape on the back side but I do kind of like the idea.
I like the example tank you showed that looks like a great 'fuge!
Tim
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"The moment you doubt whether you can fly, you cease forever to be able to do it..." J.M. Barrie
Current Tank Info: 210 AGA RR, Apex, 3x Kessil A360W & 2x 80W T5s, GEO 618 Ca Rx, BM220 CS2 skimmer, Tunze 6100s, 42" ETSS/AE Tech refugium/sump
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