All of these questions have been answered in more detail if you search the forum.
The hardware you have described should be plenty powerful. Search the forum for more on hardware sizing, try the hardware forum.
I would replace your current router and have the pfsense box be your only NAT and firewall. Will simplify things.
Almost any network card will do, but see the HCL on www.pfsense.org and know that Intel cards are the best, and Realtek cards are the worst.