I'm gonna try to drill an overflow for my 39g. What size bulkhead would be sufficient? I don't want to go too big because I want to minimize wasted space.
No I mean what kind of return pump are you going to use. How much flow do you want through your overflow? Also are you drilling the bottom or the back of the tank?
Most tanks I've seen and or have done myself that are less than 40g are using pumps that are compatible with 1/2" return and bulkhead. So if you're going to drill for a standard bulkhead fitting at 1/2" size you need to drill a hole 1 1/8".... if schedule 80... 1 3/8".