Good Question, have to include them in my list
1) Commander overrides the Born to Lead trait (can be considered as Born To Lead 5)
2) It should be Crossbow right? d12. Laura in Example has very old crossbow ;-)
3) 0-4/4-12 at least I play it this way. I did not sent the FAQ/Errata to Jamie yet for ruling
4) page 49: On occasion, a warrior may have gained so many XP that not only does he cross
an advancement threshold but he also increases in rank along his chosen career path.
This may simply mean the fighter has in increase in status amongst he’s peers, but
on occasion it comes with benefits such as access to additional types of Trait Charts.
RAW you level up as usual but get a new traits list open. Your Born to Lead will not increase to two. I think, that may be you can choose to do it instead of rolling on new trait table as soon as you reach the appropriate level.
5) no ruling, I would suggest that you will mark that he has wound to his eye and in case you are wounded again he will be removed.