Yes quite a few running Hoglets about, maybe if I get round to finishing mine it will too.
I went with all CI but again have seen others with ali outsides and a CI sleeve
Again I have gone for the o rings but if building again would probably opt for CI rings which is what I usually use and most hoglet builders seem to get better results with iron rings.
Yes the bronze is heavier, brass may be cheaper but look at the hollow bronze as you are not paying for material that will end up as swarf, I use 4" nominal OD x 3" ID if I remember rightly, it comes a bit larger than 4" so you can get the finished size out of it.
If my crank slips I will add a light straight knurl and also extra slots.
Have a look at Nick_G's recent build thread as he departed from the plans for crank and flywheel.
http://www.modelenginemaker.com/index.php/topic,5947.0.htmlJ