That was my question. How tight does it need to be, I have mine a little tighter than finger tight.
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You will create an air pocket if you reverse the scupper, also the holes will not line up if you reverse them and you will have to put 4 more holes in the bottom of your boat. I asked the same question to wakemakers, and they said reversing the scupper was not recommended because of the air pocket it would create.
I can say, when you grind off the scupper it works great.
I purchased all my brass fittings at Home Depot, not sure what you are refering to about the brass bard for the shut-off valve. My ball valve is threaded to a 90 degree bend off the intake.
If you run your boat in mercy/dirty water often you could always add an inline filter. After an entire year of running my stock Supra ballast system I had very little debris in the filter they had on the stock system. Not that it could not suck anything up and ruin a pump, anything is possible. I elected not to re-install the filter again because of space limitations and its another source of friction loss to decrease your flow rate.