So this was pretty easy and it's a great function.

1.) lets create a button
1.A) /includes/languages/english/YOUR_TEMPLATE_NAME/button_names.php

add:
PHP Code:
define('BUTTON_RMA_REQUEST''button_rma_request.png'); <-- Name of your button
define
('BUTTON_RMA_REQUEST_ALT''Request an RMA'); <-- You buttons ALT (alternative text
1.b) upload your button
/includes/templates/YOUR_TEMPLATE_NAME/buttons/english

2. lets add the button to the My Account > History > Order Info page
2.A) /includes/templates/YOUR_TEMPLATE_NAME/templates/tpl_account_history_info_default.php

I added my button at the end of the file right after the <br class="clearBoth" /> and closing </div>

PHP Code:
<div class="rmaRequestButton"><?php echo '<a href="' zen_href_link(FILENAME_RETURNS, (isset($_GET['page']) ? 'page=' $_GET['page'] . '&' '') . 'order_id=' $_GET['order_id'], 'SSL') . '">' zen_image_button(BUTTON_RMA_REQUEST) . '</a>'?></div>
3.) /includes/modules/pages/returns/header_php.php

find:
PHP Code:
if (REGISTERED_RETURN == 'true'){
  if (!
$_SESSION['customer_id']) {
    
$_SESSION['navigation']->set_snapshot();
    
zen_redirect(zen_href_link(FILENAME_LOGIN'''SSL'));
  }

right below that add:
PHP Code:
if (!isset($_GET['order_id']) || (isset($_GET['order_id']) && !is_numeric($_GET['order_id']))) {
  
zen_redirect(zen_href_link(FILENAME_ACCOUNT_HISTORY'''SSL'));

towards the bottom find:
PHP Code:
  $city $check_customer->fields['entry_city']; 
right below that add:
PHP Code:
$customer_info_query "SELECT customers_id
                        FROM   " 
TABLE_ORDERS "
                        WHERE  orders_id = :ordersID"
;

$customer_info_query $db->bindVars($customer_info_query':ordersID'$_GET['order_id'], 'integer');
$customer_info $db->Execute($customer_info_query);

$order_number $_GET['order_id']; 
Thats it, now your customers "Order Number" text field on the returns page will be pre-populated by the order_id from within the My Account > History > Order Info page

Enjoy!