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Steve,
A couple of points.
1. Do not put the return fuel into the same area as the pickup. The fuel is heated by the pump and the routing through the engine compartment. Put the return as far away from the pickup as possible to reduce local heating at the pickup.
2. If you have a foam filled tank you can just let the fuel dump onto the foam. You will not get aeration. But, if the tank is open, you will need to aim the fuel at a sidewall to keep aeration from occuring. A 30 degree angle to the wall works well. This allows the fuel to contact the wall and spread. If you just allow the fuel to dump straight into the tank, you will have aeration and vapor increases.
3. Bob is correct. If you can cool the fuel on the return leg you will be much better off. We regularly use a air/fuel cooler on the return line to pull the heat out as much as possible. Porsche (on the 928) has a return cooler that is plumbed into the AC system.
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