1. 78 main / 33 intermediate. I also have the 600 cam/zero decked and S&S big filter. With a stock cam I'd suggest maybe a 76 main and 31 intermediate, or even leave the stock main alone. Much also depends on what part of the country you live in as far as final tuning goes.
2. No difficulties tuning, it was a breeze. Just follow the tech bulletin from S&S. The bike runs extremely strong.
3. I used a piece of 3/16" flat stock steel and bent it in a vise similar to a "Z" shape, then angled it downward a tad to match up. You'll have to drill it in the appropriate locations of course. No big deal.
4. All chrome pipes will blue, these took awhile. I do have heat shields but I have yet to install them. I use a product called "Blue Job" to polish the blue away. It was fun asking the young girl behind the counter "I'd like a Blue Job please." lol
Here's a pic of the bracket:
