1. If you want to do that (I don't bother) then every other carding. But seriously I find it creates more broblems than anything else.

2. As above.
3. Do you want the barrels to have a black twist or brown? If black logwood boil after the last pass.

Don't forget that you need to neutralise the rusting action too. So drop them in caustic soda at 70 or less degrees for 90 minutes.

Cheers
T