Glad you are nearing the end and its getting fired up tomorrow!
On issue #2. Are you talking about the bumper support or the hood latch support? The hood latch support is a small metal piece about 5 inches long. The bumper support is a giant compressed Styrofoam log.
On #3. All other forced induction kits delete the PCV and run breather filters to atmosphere like I suggest. The only reason stillen has it recirculating back into the system is to pass CARB.
On #4. You stated the use of stillen tank as an only option but the best option is to use the Factory overflow tank in the factory location.
I am not a huge fan of the way the 45* coupler is coming off your intercooler. I know it can be tricky dialing that Y pipe in to fit just right (but much easier than routing turbo piping all over the place) , but Its possible. Cant you clock the Y pipe clockwise about an inch? That should alleviate that small bend in your 45*.
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