Ok guys here is an update. I got a reproduction hemi fuel pump (3/8" inlet) and basically replicated the factory setup. I had to rework the hard line from the vapor separator to the carburetor but I think I got a working solution. I am not crazy about running a rubber hose right around the distributor.

I measured the fuel return orifice with a set of drill bits and found it right at 7/64" which comes out to ~.102 inches. Doing the math, this comes out to around 12.2% of the cross section of the main 5/16" outlet. Would this be too large or am I ok?

I pulled the sending unit and it looks brand new in every way. Sock is perfect and no corrosion anywhere. I had to re-open the return nipple to plumb in my line when it arrives this week. Once I have the return line and the AN to 5/16" nipple, I should be able to start testing this out.

Is there anything else I should do while the car is 'down' to help combat this possible vapor lock?

Thanks for the help so far.