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I was on the track (Derby) last night and noticed at least a couple of people had 5mm showing either side. It was a club session but maybe a bit showing is generally acceptable.
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I cut and filed mine back rather than risk being told I couldn't ride; they're Miche hubs but on a very second hand and mistreated track bike.
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If it's your first TT then do it on your road bike, no point spending money on something you might hate.
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I can't, but with the right machine, welding rods and skill set, someone could.
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TIG is the only welding process I know of used for bike frames currently. Brass brazing doesn't actually weld, it sticks the tubes together without melting the base metal
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There was an arc welding system used briefly after the war (I think) that didn't use any filler material, the tubes were pushed together at high pressure and then a high current was passed through them that fused them together at the joints. It never really caught on, I'm guessing the tooling was not versatile enough for the bike industry.
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TIG I would guess, I don't know. Problem with MIG is you're melting mild steel wire into a chromoly tube (well one of the problems), with TIG you can choose a more compatible filler material.
It was never for sale (well not since Hilary Stone sold it to me anyway) and it never will be; it is a thing of joy, except when I'm time-trialling on it, when it becomes an instrument of torture.