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Copper returns?

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in Strictly Steam
Our house has an 82 year old low pressure steam boiler feeding a 1 pipe system.  It's working fine, but we're planning for a new boiler.  Someone suggested replacing the returns with 1-1/4" copper.  I read the thread on "Badly Maintained Oil Boiler", but still have some questions.

1. Is it true that with steam heat systems (unlike waterline plumbing) there is no dielectric corrosion problem at the joint between copper and iron?

If I do add copper returns:

2. At the far end of the mains, where should the transition to copper be?:

     a) As high as possible (just below the main)

     b) Below the boiler waterline

3. At the boiler end, where should the copper change back to iron?

4. With 2" mains (2 of them) and about 470 sq ft EDR, would 1" copper returns be adequate?

5. Wouldn't the leftover flux from soldering create a foaming problem?  How can I purge the flux?
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