I am trying a different approach to "preventing" tubing collapes. I am going to setup my new pump with a 3/8" pressure side (pump -> water block -> radiator -> res.) and a 1/2" return line ( res. -> pump).
My reasoning behind this is two fold;
1) The pumps are made with a larger intake line and a smaller exhaust line by nature. Might as well stick with the pattern.
2) I believe that most of this tubing collapsing is due in part by having a completely closed loop system (no place for the water to truely "sit" for any length of time and the pump is trying to both SUCK and PUSH the water through the loop at the same time.
I want my pump to push NOT suck; where doing so will create a low pressure spot just before the water enteres the pump.
I designed my setup so the water was always being moved from the lowest point (pump) to the highest point (res.) and then gravity would feed the water back to the pump. Increasing the return line size helps to make sure that gravity will be able to feed my new pump enough water to keep it from trying to "suck" water in.
That is my theory and personally it cant hurt one bit to do it this way. So far I have yet to see ANY stress or tube collapses in any part of my setup and plan on keeping it that way