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Nice job.  Mill is nice as is the lathe sitting to the right just out of picture.  The ones I made are wider but really just to fit the included chain guard.  The actual bushing/spacer width is only 6.5mm, mine are 16.5mm.  My RD frame and I assume all others measured at 200mm wide for the swingarm.  Bushing both RD and SR is 197mm and the Motolanna swingarm is 187mm.  OD to fit the chain guard was roughly 35.5mm.

Finally got around to make the bushings to fit a Motolanna SR500 swingarm to an rd frame. Will tackle the wheel next. Pretty simple and a cost effective choice for an aftermarket swingarm.

2R9 would be different than a Daytona which most people would associate with 400f, at least in the US.  I do not have a stock bike but you don't want to go huge.  Maybe start 3 (160-170) mains bigger and then work back from there.  Air screw and idle will let you know if the pilots needs to be changed.

Why wouldn't you?

Pretty common modification/weight loss procedure on race bike destined frames.  I believe all of the RD frames I have purchased as road race frames with the exception of a Daytona that the builder wanted to be able to return to stock had the cross member removed.

Been a lot of years since I last saw this talked about but there are people on the board who have done this I believe.  The short answer is yes the 400 tank can be mounted on the 350 frame once you make the rear mounts.  However, there could be other issues on a stock 350 to watch out for such as seat interference and clearance under the tank.

I know the head pipes are different between the RD400 and the Daytona.  Do the mufflers interchange though?

112mm is correct, or at least what I came up with when building brackets to mount different calipers.