Q1. The gate valve, I heard it ships with schedule 40 but spears schedule 80 is way better for tuning. Can you confirm size? It looks like 1 inch threaded.
It is 1" threaded. Not a bad sch40 gate valve. I've had no issues dialing in due to the valve. I do have a Spears which I will likely use and can comment on later.
Q2. The intake to mazzei, it looks like 1 inch looking at random pictures, I'm assuming you down sized it to 3/4 inch?
It's not a mazzei, it's the stock venturi. The output from the Vectra M1 is 3/4" and that's what feeds into a 1" intake of the skimmer.
Q3. What step did you end up running pump at after breaking it in?
Right now I have the Vectra running at 45%. I was running it at 100% and the only problem I had was with it raising my water temp. The Lifereef has no issue with handling that pump at 100%. It works at 45% or 45w. The heat isn't as much of an issue but my house temp has dropped to about 71F with the outside temp this week. It will be back in the 80s this week so that will be the test as I keep my house at around 75F with A?C. I think there was better foam when it was running at 100%. It seems the faster the pump the better.
Q4. If you had choice over would you have gone L1 or is that too much pump and M1 more than fine ? ( L1 is 1" output, M1 is 3/4" ). The L1 is also about 1k more gph.
The M1 is fine, probably more than fine. The M1 @ 2000gph is a lot of flow. If you have no concern about heat or will run the skimmer externally you could try the L1.