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Message: [QUOTE="TARM, post: 995513, member: 578"] Your return line size is dependent on the volume your pump is sending thru the line. Think at idle its using next to no fuel. Almost all of it is going back to the tank. The need to increase the size of the return line itself when it becomes a restriction to the fuel flow returning to the tank. The way you know this is when you can not control the max fuel pressure with the regulator. Say you keep trying to lower the full pressure by opening up the pressure regulator yet the pressure does not drop or stops dropping at a certain pressure which is at or not much lower than the pressure you want to run at. That is because the fuel is flowing as fast as it can thru the return hose and to run faster the pressure has to be higher. Thus the return hose because what is controlling the min pressure in at least a low fuel use state. A every easy way is to always make the return line the same size as the feed then there is no way it will ever be the restriction. But normally a 3/8 line is usually plenty. Unless you are pushing serious HP no way it will need more than 60-70 GPH. Two dual stockers or one 044 is plenty for at least 600 HP. As the fuel lubes the barrel and plunger any drastic fuel drop is a bad thing and if severe can ruin injectors. IMO go ahead and do a full RR. I would always do the tank mod even if I had a stock motor and fuel pump. The reason you can not simply add a second pump on with a couple Y connectors is the PU and feedlines will likley create enough resistance and over work the pumps and end up burning them out. There are almost countless ways from basic to complex that you can build a fuel system. I would stick with something basic but do a full fuel system. You can use the OEM feed line as the return to save some money. But at a min I would have a pick up pre filter water sep pump post filter and then Y up top each head. Y out of them into the return line. There are all kinds of threads on here for fuel system builds. Pick one and follow it. I know I have put a number of them up with part numbers etc as have others from basic to wild. [/QUOTE]