Good questions Jason. Since this was a review on the figure itself, I didn't want to put to much in the review about the decal process. But answering those questions here is perfect and this is what the thread should be used for.
I purchased the decals from
www.spruebrothers.com. The have the whole assortment of CrossDelta decals to include all the US uniform types. Yes, I do all the decal work first, seal that in with clear flat and then paint in all the other details. I use Walthers Solvaset, it seems to be the strongest and you need a strong setting solution for these decals. Work in little sections and try to use the actual seems to place the decals. Use a brand new X-Acto blade to trim and cut.
Hope this helps.