[saschak]

Hi,

I'll answer your questions quickly as I have not much time.
1) You need to have some space left before you may increase the FS. A 100% full FS can't be seized.

2) It's up to you. Binaries (executables) should go somewhere to /bin, /usr/bin, /usr/sbin, /usr/local/bin, /usr/local/sbin, ... the main thing to keep in mind is that these paths are in the $PATH variable so that you dont need to enter the full path when running a bin.

3) Yes you can, but in case you have files in that directory, they will be overmounted by the new filesystem. They won't get lost, but be hidden when you mount the FS.
My 2 cent: Move the files to a temporary directory, create and mount the FS and then move the files back there.

HTH
Sascha