Hi Joe!
Glad you could stop by, call me santa any day

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1) Yes they have. The reason for this is the extremely advanced clipper back-end in Breakaway FM.
On the FM medium, we have pre-emphasis to deal with -- audio must be broadcast with a very sharp treble boost (subsequently EQ'ed out inside every tuner), and all this treble causes peaks. These peaks would cause overmodulation and would mean we'd have to turn down the volume by at least 10dB, leading to a very quiet and/or dull sounding station. So, BaFM does not hold back -- it does the best darn job possible, but it does need some CPU. Not that much by todays standards though -- it runs fine even on the cheapest dual core cpu (Celeron E1200, $49) and uses only 10% on the cheapest core 2 quad (Q6600, $189).
BaFM absolutely takes advantage of dual core systems.
2) The cleaner the chain is after BaFM, the better. You'll get the very best sound from completely removing the David II from the chain and using BaFM's MPX output directly into your exciter (with a 192k sound card). You'll need to use an oscilloscope to adjust TILT and MPX PEQ to compensate for your sound card, but once you've done that, you will probably have the cleanest and loudest station in town (at the same time).
If you must use the David II stereo gen, turn off its processing as much as possible. Any crossovers, filters, clippers or compressors must be completely disabled, as they will cause overshoots for no gain. BaFM's output signal is already STRICTLY low pass filtered to 16 KHz, leaving 3 kHz of pilot protection. The David II would have to run as a straight stereo-gen with no other processing at all.
3) Got paypal?

. It's not officially for sale yet but I can sell you a copy now, and you will of course be able to use your license key with the full version when released.
4) The crossover cutoff points for the 6-band presets are: 36, 49-145, 171-507, 599-1775, 2097-6212, 8235. Note that the first one is low-pass, the last one is high-pass, and the remaining ones are band-pass.
I've already worked for Bob a long time ago, before Octiv got started (1999) -- not happening again, but there's always Frank

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///Leif