I"m drilling three holes on a 46 bowfront tank. One is for the drain, 1", and two for returns. My question is, what size do you guys recommend for the returns? 1/2" or 3/4"?
Its all about the head pressure. The hieght you are going up and the amount of elbows(each 90 el accounts for about 1ft of head pressure). So the pump matters. The pump should have a chart showing the head and flow rate at that head. It will alos state what size pipe. If not you can google pipe flow rates...
However in your case using 1 - 1inch drain you will probably be good with 1/2 inch. What I usually do is plumb a Tee with a ball valve coming off the main return line (discharge side of the pump) this way if I find I need a second line it's very easy to plumb later.
btw I always go over the top with my return too. Less holes in the glass the better.
Good luck