Your return line is really dictated by the size of your pump, bigger pump bigger line. 3/4 inch I'm sure will be fine, what kind of pump are you going to use. Maybe an Aquamedic 3500 or something similar.
PVC comes in ... slip or thread, slip being glue in, thread being threaded. So you can do either or both or any combo. The PVC will connect to hose with a threaded section and a barbed section for the hose and a hose clamp.
PVC glue is aquarium safe, once dry.
Hope that helps. Unions are also nice so you can take things apart easy; some ball valves come with a union, which is what I use. (Western Pump)
It's like a puzzle map it out, go get parts, go home, go get more parts.....
Dave
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