If you're VIP the return is prepaid (I have done it many times). You have to ask for the receipt at Kinkos - they'll scan the label, and print a receipt. I always do that, I don't want to be liable if somehow the package gets 'lost' before they scan it in.
Oh - also, you don't absolutely have to get a RA (return authorization) number from ELX - sometimes I do, sometimes I don't.
You don't have to get additional insurance. Since ELX is paying for the shipping, and the shippinnumber goes into the Fedex system, if it gets lost, you do not have to do anything, it is ELX that has to search for it and file a claim if necessary. Another reason I make sure the package is scanned in at Fedex/Kinko's before I walk out of there.
Hope this helps.