1) ft101 already posted the relevant link. No idea why though. It's 150k, not 145k.
2) Doesn't really matter. You hardly ever need the card. You can log in and print out a temporary one to be on the safe side.
3) 500 total.
4) Give your Skysurfer number at check-in in the hotel.
5) Probably not. Ask, but don't expect them to say yes.
6) That would definitely work as Skywards, don't know about Skysurfer. Try this link:
http://www.emirates.com/account/engl...w.emirates.com to sign them up.