Ok, so, im going to modify it some (hopefully reuse all the pipe) and add in the points brought up.
-Add bypass loop from supply to return.
-18" of straight pipe before the air seperator
-No 90* between loops(will probably shorten the Primary loop too if I can)
-Try to heat those plugs ...otherwise, guess I'll drill.
-Yanche: I read and re-read your post several times trying to picture and understand(Im very new to all this). I THINK you are suggesting putting the primary circulator low on the return end of the primary loop, so that the zone pumps dont get starved of water in case of a blow? So the primary will, in a way, be pumping 'towards' the boiler, and the zone circulators will still be 'pumping away' from the boiler, correct?
- Does it matter which order I put the flow control valve, air seperatpr(as long as it has 18" of straight before), and primary loop circulator? Given the new suggestions,(and assuming i got what Yanche was suggesting) I'd like to put the flo valve first in place of the tee at the top of the initial vertical supply pipe, and use the two inputs as I would have used the 'T'...the after the 90* along the wall, have 18" of straight, then the air seperator, the the tees to the zones and tees for return, then the priamary loop circulator on the return-half of the primary, right before it splits to (2) 1" return lines.
-If I split the returns, Being that the initial supply is 1 1/4" pipe, Is there any reason I cant make the split returns each 1" because the flow rate of the 1 1/4 is 14GPM and the combines rates of the (2) 1" pipes would be 16GPM. Logically, that should work, right?