1- good idea
a- the former
b- the Caprice- push pull in does increase turbulence and pressure, but you have more surface area and the probability of more airflow with two fan in parallel on a Caprice
c- larger means more surface area and more space for fans- all cooling systems come down to airflow, I say keep the larger heaterfore if you have the space
2- not a good idea
a- it really depends on your system, and how you position elbows, but I recommend you find some way to work with 1/2"ID because of the benifits of lower restriction as compared to 3/8"ID
b- as far as I know, only elastic tubing can do that, such as vinyl ones like Eheim; pour boiling water over the ends and give it a shot
3- a- should be fine if the barbs don't have too small a nipple
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