The lower port of the plenum has a weird oval shape that IIRC is larger than the TB opening. If you want to hand port the plenum, open the TB side to 75mm if you can, and want to use a 75mmTB. The other place the aftermarket plenums are larger is the long side (outer ) radius of the 90* bend. Go look at pictures and you'll see what i mean. The bottom I would gasket match if I did anything at all. Just leave the short side radius alone, it seems messing with that usually does more harm than good.
It's not necessary, but you certainly can if you want to. I think it's more about smoothing the air flow than making more air pass through.
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