According to http://www.lightaircraftassociation.co.uk/engineering/Mogas/Rotax%204/Inspection%20checklist%20LAA-IC-ULM-ROTAX%204%20STROKE.pdf, I can expect about 3l/h of return fuel. If I fly farm patrol, I'm burning less than 7l/h, the error will exceed 40%. When I cruise solo I burn about 11, the error will be 25%. Since I cannot install meaningful tank level gauges, I have to rely on a fuel totalizer in conjunction with level switches and a sight glass on the last tank. So an accurate totalizer reading is important, but not more important than avoiding an engine out.
This is what I have now. There is another option. The return line connects about 4" upstream from the mechanical pump. I can take that connection down to the boom of the aerie, where the gascolator sits. This would give me an additional 40" of vertical hose and hopefully give me some kind of pressure head that the air will find difficult to bypass.
HawkFuel.png (You do not have access to download this file.)