I might be shooting myself in the foot for not looking it up, but I believe the range is 0.667T to 4T. T in your case is 0.035 inch. As for the fillet welds, as you said, 0.063 inch is the minimum material thickness, unless a fillet weld test is performed on the minimum thickness (less than 0.063 inch) used in production.
The rest of your questions will need to be answered by studing the applicable welding standard which is based on the requirements of MIL-STD-1595A (no longer supported by the military).
Good luck - Al