I can only help with #1...
Marc S on the forum maxed his D1 out in the mid 700's with GT500 pump, 60# injectors, and a BAP with the stock return less fuel system. He was over 95% duty cycle though IIRC. I believe he has upgraded to a return style system now.
I had it on the dyno today, repaired the FRPP TB and put it back on. I also fixed some drivability issues. It put down 705whp on pump gas. The GT500 pumps w/BAP, 60# injectors are just like you said, 95% duty cycle. On race gas, the fuel system is maxed.
I have not upgraded to a return system yet.
marc-how much boost ?
well I'm sure the cams helped also. Did you do any head upgrade?
It sounds I should be able to get to 600rwhp with the SC upgrade alone.. I hope..
I was not sure if the SC alone was holding me back.
Great.. so even if I hit 15+psi on the ds1 I might not hit 600..haha..
I didnt want to mess with the cams or heads at all.. its just more shit to go wrong with my luck
With the stock engine and headers, I made 569/481 with 15lbs.
Ok, got my unit mocked up and standing by. So have all you ProChargers guys used the issued hose clamps with no problems?
I was thinking of using T-bolt type clamps just to make sure nothing comes loose. A little wider and more secure clamp; but about 5 bucks each!!!! Times 16.
Can always use that money elsewhere
Thoughts??

I used to clamps that came with the kit everywhere except where the intake pipe mates up to the throttle body. During the first two dyno pulls, at about peak boost, the clamp popped flew across the room. Swapped it out for a T-bolt clamp and never had another problem.
let me introduce you to ebay sir...
http://cgi.ebay.com/ebaymotors/20X3...r_Truck_Parts_Accessories&hash=item4cf2d2b44e
3" t-bolt clamps 20 for 36.99 shipped...
2.5" t-bolt clamps 20, same price...
http://cgi.ebay.com/ebaymotors/20X2...r_Truck_Parts_Accessories&hash=item5add362d41