Very nice run down and it deserves more of a reply than I can squeeze out this evening.
I think you have enough facts about your parts. You will no doubt end up in good shape.
The 6061 and 7000 series won't give any trouble... The unknown gummy stuff will take some test runs but it looks like you are very organized. Keeping track of all the parameters in your test runs will help you figure out what will and wonít work.
Considering all the long hours you have put into this project itís got to be a scary step for you to take.
You might want to experiment with ASF when you get started. The lower the ASF the easier it is to control the tank temp. ButÖI have found the lower the ASF the softer the final ano finish is. You might very well be satisfied with your parts at a lower temp, and not have to worry about cooling the ano bath.