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even considering relatively lower federal tax rebates for 2011, i believe it's still worse it to install a tankless water heater.

http://www.strictlytankless.com/

The easiest way to size is by measuring your furnace plenum and then choosing heat exchanger that takes the most part of it. For example, if plenum size is 17"x19" or 17"x21", then heat exchanger...

Yes, there are lots of things to take into account. Therefore, it is recommended getting a local experienced contractor. Fixing mistakes is usually more costly than paying an expert to get radiant...

I think you should go with your contractor recommendations. Your systems looks a bit complicated.

You can learn more about manifold sizing from people that sell manifolds, like...

Generally, you don't need double wall heat exchanger unless you have potable water on one of the sides in your system. For example, in radiant heating systems for snow melt is widely used 30%-40%...

I believe your contractor is right. Replacing pump every few months will be even more expensive, just consider the cost of pump itself, which is $70-250. For example, Taco pumps...