What if you just attached the powerheads to a strip of acrylic that could be suspended into the tank instead of trying to modify the sides? That would make the powerheads easier to remove for cleaning and avoid any future problems, i.e. if you change powerheads in future and the replacements don't fit your routed depressions.
Dave.M
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My Gawd! It's full of corals!
Current Tank Info: None. Nil. Zip. Nada.
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