Originally Posted by ReeseAllen
I was thinking a smallish hole saw would probably be my best bet. I need to drill a hole big enough for a 1/2" pipe, so like 3/4" diameter. If I tried to use an ordinary drill bit for that it'd probably end up making a really gnarly hole that's damn near impossible to seal.
I kinda like having the manifold unsoldered because I can break it up and drop the pieces into a bucket of oxy-clean water and clean them really easily. Rinse with hot water and put it back together and it's ready to go.
You can always use a step-bit. I don't have a pic but it looks like a large triangle and will gradually increase the hole size to 3/4". It's more precise then a standard drill bit, but for drilling plastic I think it's overkill and you'd do fine with just a normal bit if you go slow and drill a pilot.
As for taking the manifold apart I can see your point, I just take mine out run hot water through it then use compressed air run through it the day of brew to blow out any remaining grain. I don't bother sanitizing anything pre-boil it's a waste of sanitizer. I do however sanatize anything used during the boil, IE stir spoon, and everything post boil, CFC, Fermentors, caps, airlocks, etc. That's just me though.