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Is it typical to see sludge like that in the distribution box within 4 months of installation? It is normal to have some liquid in the distribution box, depending on how low the output pipes to the drainfield are mounted in the box. Liquids flowing in should flow equally to each of the output pipes. You should not see solids in the D-box.
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If you truly want or need to flush mount, than careful measurement and slowly working your way along to mount the boxes "not on a rib" as you lay in the tin will be essential. Use a step drill to get the initial hole, and a nibbler tool to cut the tin out.OP, you mentioned 3/4" holes (which won't fit a PC cord but will fit armored cable (AC/MC). And you mentioned armored, so I assume this is in-wall wiring which is proceeding through built-in style cabinets.
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