I'm running a 148 zxi pump in my FX1. I'm running a 11/17 solas swirl and a 87.5mm nozzle. I'm running a Dasa 850 with a single 46. I would suggest a 9/15 or 10/16.
61x can work very well with larger motors:
http://www.x-h2o.com/index.php?threads/61x-scream.104032/
http://www.x-h2o.com/index.php?threads/61x-dasa-850.114371/
5200 is not made to bond to metals without applying a primer. 3M makes 4000 that is a fast cure and intended to bond/seal metal to fiberglass. It's very similar to the stuff the factory uses on the cooling lines.
I haven't noticed any downside to maintaining the stock pump tunnel. I've been running the same set up on my other FX for over 2 years now and it rips. I think you would want to change it if you were trying to build build a flat water ski, but for surf and wide open high speed carving on flat...
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