I'm not sure what size hose I'm running, but it is slightly wider than the stock feeds to the SUs. As for the lines, I don't see why a return line would be bad and the Z is already set up for it anyway, and why remove the rail for that matter. I kept the fuel rail (and the mechanical pump as well) and am using the return on my triples.
My suggestion:
Tank > Filter > Mechanical pump > Rail > Hose into front carb > Connect carbs > Last carb feeds back into the rail > Return
If you want to run a fuel pressure regulator, then place it after the carbs with a return line present and you now have better regulation and fuel flow since you are regulating the back-pressure and have a bypass for excess fuel. Only excess fuel goes past the regulator instead of the method you mention, which would put a restriction without a bypass and effectively heat the fuel before it even gets to the engine bay. Plus, with a dead-headed setup the fuel then has nowhere to go and further heat up compared to a return line and a back-pressure regulated system.
Of course, I am not saying that your setup won't work and I'm sure many have used it and were okay with doing so. However I prefer the better option especially since the car already has the required provisions. If your Z is just a street cruiser then you probably won't have a problem with the way you were originally told.
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