Or instead of running the entire return line 3/8", use a short piece of 3/8" on the block and then put a 3/8" to 1/2" reducer on it so the rest of the line could be 1/2". (regarding the mb tray, you wouldn't have to 'carve out' a hole, just drill a hole large enough for a nut driver to fit through, about 1" would be large enough)
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