Offset or digital? Digital you could tweak at the printers if you had to.
If decent printer you should be okay. The stroke is a bit of a patch job but should give you a little bit of breathing room (I've done it before), don't think you need to go for the Bold. As Dave says massive difference in weight.
10pt will be fine, no stroke needed.
It's a san-serif so you're not going to lose the serifs.
i guess all you can do is drop ink coverage down & ask printer if they can hold detail on that stock, if they are concerned i'd be talking to client to up from 8pt
what can happen is the person working the press will adjust it and the colour will change anyway, i have worked at print houses where the chap on the press knows more than anyone else and can work wonders
let's be honest here, some text clients are not too bothered about it not being super clear, if you don't make the client aware of your concerns it may back fire on you