Hmm, sorry I can only answer a couple of your questions.
5. One is ground, the other two are low and high speed. On mine, I think the blue wire was the high speed. Just hook the wires up to a battery, and you'll see which is ground, and the different speeds.
6. On F150online, I've heard that our engines like being around 202F. You could get an infrared thermometer, and point it at the radiator, and set the controller until the radiator is around that temp. Then again, you said you had a lower temp thermostat, so I don't know exactly what that would do.
7. I've always just called them zip-ties. If you call your local Autozone, and tell them you're looking for zip-ties that fasten e-fans to radiators, they should know what you are talking about.
As for the other questions, I honestly wouldn't know how to answer them. Why don't you go on over to F150online.com. There's a couple people there who have used relays and what not to set up their fan(s) and would know how to answer your questions. I used a DC fan controller, so that made installation much easier.