You shouldn't take legal advise from people like me that isn't a lawyer that knows all the ins and outs of NFA laws. They are fairly arcane and in some areas open to interpretation, so getting a lawyer that knows this stuff to advise you is probably your best course of action. But I'll tell you what I did, and give you my opinion.
1. I was having the same problem. For me, I was debating between a 10.5, 11.5 and 12.5 length barrel. I did not file form 1 until I decided for sure the barrel length I was going to buy. This added a couple of weeks to the cycle, but I wanted to be sure. I'm not sure it matters a whole lot, since you can use that same registered lower receiver with a variety of other uppers with different calibers and barrel lengths. Just not sure that at least one of your uppers has to match what is on your form 1.
2. You do not include the length of a muzzle device. The overall length estimate should be from the end of the extended stock to the end of the barrel without any muzzle device.
3. List the rifle in schedule A as you have filed in Form 1. That is, the manufacturer of the lower receiver, the model number of the lower receiver, the caliber that you have in your form 1, and the serial number of the lower receiver. No lengths are required.
4. I have not.
5. I don't know. It depends on what kind of stock you will be using. If you have a fairly standard collapsible carbine stock and receiver set (like B.A.D.'s), it's more like 18 - 19 inches + barrel length.
I'm not a lawyer, I could be wrong.