I suppose you are going to install the fitting where you are pointing on the third picture? I am going to install the kit soon, so if I can get a new idea, I will try it.

 

it clears the street kit.... the line makes a nice path from the bottom of the turbo, in between the power steering hard lines and oil pan, along the side of the pan to the fitting.

The good thing about this location versus up front from the bottom is, if a cup of oil goes in the turbo, a cup comes out, whereas when the return is in the bottom of the pan, oil always sits in the line until the oil right out of the turbo is heavy enough to push the oil up the fitting and into the pan... oil should never sit in the return line. Every bit of it should exit out into the pan. Also when the car accelerates, this will help the oil move out of the line is the majority of the line is parallel with the cars direction.
The measurements i got are 4" up from the bottom of the pan and 1.5" left of the front of that pan reinforcement vain... but it is hard to get an exact measurement as the vain is not perpendicular to the bottom of the block. These measurements are to the center of the fitting, 1/2" NPT... same as MM. And i used his 3/4" hole saw on a right angled drill with a vacuum cleaner sucking the shavings while i was drilling. Just be careful about the section you cut out, you don't want it to fall in the pan. A little grease in the hole saw will help. 3/4" is actually a little larger than the required drill size for 1/2" NPT but i was unable to find the right size (45/64") in in a hole saw and my right angle drill only has a 3/8" chuck... so the right jaber drill bit i should have used would not have worked. The 3/4" is actully a little better i think as it was much easier to start the tap.
I marked those measurements and made sure once drilled that the fitting had clearance from the vain and the bottom of the pan/bolt head before drilling.

I say compare what numbers MM's gives you, along with mine and call George to see what numbers they wrote down. I know when i am making stuff at work....I always try to stick with even numbers/fractions where i can to make things simple.... and figured George did the same.
Lastly.... call George on any oil return issues. He said the main issue is because of too much crankcase pressure, were as it only takes 1-2 psi to stop the oil from coming out of the turbo. It doesn't take much to create a couple psi if the pcv is not sufficient(large enough filters), if the one-way valves are leaking with boost, and/or there is some blow-by.

 

go with jarrods measurement, he musta measured it 4 times.

 

When i took off my oil pan saturday i saw some webbing (two ribs) inside the pan that would be a great place to put the return line. This webbing would keep the oil from entering the drain hose when the car moves sloshing the oil back and forth. Ill try to get some pics of this webbing next saturday.
only thing is though i would not want to drill into the webbing.

 

I'd put a weld on fitting higher up on the side of the pan. Since it's welded on you don't have to worry about anything protruding into the pan and hitting your rotating assembly.

To find out exactly how high the oil sits in the pan why not fill an uninstalled pan with quarts of water?

 

how much oil is sitting in the engine while moving though
not all 5 quarts will be in the pan.

also my fitting from the bottom (original location) stuck up another 1/4-3/8 inch which would hinder draining.

 

1.3 this was done and the level ended up being about 1/3 the way up the angled portion of the pan

 

I have a pan sitting here. How much fluid would be in the pan at any given time? I can add water into it to see where the level is.

 

Am i correct in assuming that it would be a good idea to drill the hole in the pan using grease on the bit and then change your oil right away to get rid of any shavings that might have gotten into the oil pan. Good info guys we'll get this damn oil problem straight eventually. BTW mine is smoking again after you let it sit overnight . But just untill you get out on the road and clean out the exhaust real good.

 

I would keep a Shop Vac handy as well. Greasing the bit should do the job.