A vacuum insulated glass (VIG) window assembly and method for making same is provided in which dimensions of a hole and/or pump-out tube inserted therein are selected to provide sufficient clearance for efficient insertion and accommodate sufficient adhesive material, while at the same time providing sufficient support to resist substantial tilting/tipping of the pump-out tube. A length of the pump-out tube may be selected so that a distance between a top of the pump-out tube (which is subjected to heat sealing) and an interface between the tube and frit material proximate the hole reduces the likelihood of tube cracking at the tube/frit interface.