My answers to your questions:
1. A straight board could work, but I'd be afraid of it warping with repeated heating and cooling in a hot box. A plywood form would be better.
2. 66" is not too short - especially if you have < 28" draw length.
3. 15 - 16" will work. I make mine 16", but that is on the long side for this style of bow.
4. Lot's of variables here. If I wanted to make a 30# 66" bow, here's what I would do.
- 16" riser
- 0.410 total stack with 0.050 glass and 0.005 total taper rate in the laminations
- Width of the bow would be 1 1/8" for 14" from the center of the bow out each limb, then it tapers to 1/2" at the string grooves.