1. I haven't had time to look into the 73 ft issue in Tucson. I'm wondering if its the same everywhere because when I remade the transportation data I didn't just replace the Tucson area I remade the entire state so it all should be on the same datum. I could shift everything 73ft but there has to be an error. Global Mapper normally handles projections on its own so maybe one wasn't there and I picked the wrong default.
2. I would absolutely love them. Trails are the most important thing on a topo and this one is lacking. I now know how to get all the Forest Service points (ranger stations, trailheads, etc) so I have those all set to be added for Arizona now too (they're in Mississippi). I saw your email so I'll reply there as well.
3. The last set is somewhat interesting. I wouldn't want to add it to the topo (except maybe the mines) to avoid information overload but I would want to help you distribute it to other interested people.
To create the self extracting installs the tutorial is right here and all the software is completely free:
http://www.gpsfiledepot.com/tutorials/how-to-create-garmin-topo-maps---part-9---compiling-data/