In answer to your questions,
(1) Most (all I've seen) lead-free components solder just fine with good old 60/40.
(2) You have to ask about your blank PCBs. Some use gold instead of tin/lead which is actually better. Some use bare tin which eventually tarnishes.
(3) US and California aren't RoHS yet, and as dknguyen points out, anything you don't sell probably won't ever be a problem.
(4) Your existing solder and tools will be fine until you deplete your stock. If you already have a lifetime supply, no problem.
(5) The laws apply to EU only for the time being.