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PhilDAS
Lots of tubing will have a shorter and longer butt. These are differentiated as one end of the tube is painted. I can never remember which is which so I always check with a butt checker prior to doing anything. I think as long as you have enough butt on each end (>35/40mm) it is fine. I'm sure you could be clever about more butt where stresses are highest but idk.
Yes 35/40mm afaik
Unless you are using an uber nice anvil jig (or similar) the error associated with the bb shell is (imo) pretty irrelevant. The jig isn't that straight, the frame will move when welding/brazing etc. It's nice to do but probably more important is refining your weld sequence if you want to make sure the frame is as straight as after welding. However if you have the tools you might as well do it... :)
Might be difficult to face a bb shell without a lathe or something