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Preheat the grill to medium. Cut the zucchini in half crosswise and then use a mandolin slicer to slice no more than ¼ inch thick.
Grill the zucchini slices until they are tender and much of the moisture has been removed, about 3 to 5 minutes per side. Remove from grill and set aside. (Alternatively, roast zucchini at 350F in the oven on wire baking racks for about 20 minutes).
Heat a large saute pan over medium heat. Add the ground beef and cook through, breaking up any clumps with the back of a wooden spoon, about 7 to 10 minutes. Sprinkle with ¾ tsp of the salt, pepper, and red pepper flakes. Stir in the tomatoes.
In a large bowl, the ricotta, parmesan, basil, egg, garlic and the remaining salt. Stir to combine well.
Preheat the oven to 350F and brush a 9x13 inch glass or ceramic baking dish with the oil. Lay one third of the zucchini slices across the bottom in a single layer. Spread with one third of the ricotta mixture, then one third of the meat sauce and one quarter of the mozzarella. Repeat these layers 2 more times, finishing with half of the mozzarella.
Bake 30 minutes, until bubbling and hot. Remove from the oven and let stand 10 minutes before serving.