Bill, building a polyethylene tank
is not as simple as you seem to think. Heat welded seams that won't leak require a bit of skill, and even the best welded tank is never as strong as a seamless molded tank. Nothing will bond permanently to polyethylene, so installing hose fittings requires a spin-welder (do you have one?), which also requires requires even more skill or the weld will break when pressure is put on it attaching the hoses, and female threaded fittings or barbed nipples, which you'll have to buy. The tricky part is knowing how much of the poly sheet has to be melted and how much additional poly to melt into it to get the needed strength. IMO a waste holding tank is the last place to begin the learning curve...but if you're determined...The tank walls should be 3/8", no thinner...and unless the tank is over 40 gallons, no thicker 'cuz you'll only lose capacity without gaining anything. As for the inspection port...I strongly recommend gainst installing a cover plate that you'll ever have to remove. Self-tapping screws and a rubber gasket will secure it, but only once...backing out and re-tightening screws in poly to remove the plate and put it back enlarges the holes...the screws will cease to bite. Your best bet will be to buy a retrofit kit, which is flanged and has a threaded cap with o-ring to seal it. A rubber gasket to go under the flange is included...and it's held down with screws. Beckson makes 'em in 3", 4" and 6" diameter...West Marine used to show them in the catalog, and you can still special order from them...cost is around $10-$15.However, before you do this I strongly recommend you check the tank sizes and shapes available from Ronco and compare the cost of ordering a top quality tank from them vs. your cost of materials and the value of your time (which would be more profitably spent on boat projects you're already skilled at, or that don't require any) to start up a learning curve you'll prob'ly never use again. Btw, delivery time from Ronco is two weeks or less.