>3) If I use normal toner to print the MICR symbols using an MICR font...can the bank still read it? I realize they can't use the normal magnetic process, but was curious if they'd charge more to read it manually, or if they'd just flat-out reject the check

I have a client who uses regular tonor on their laser checks and the bank has never complained. Most check scanners now-a-days MICR and OCR process checks. My guess is that the OCR software is probably setup to OCR the MICR line when the MICR magnetic reader fails. I think ABA standards still "Require" MICR to use the magnetic tonor, but I'd probably wait until the bank complains.