Sorry to hear about that, Mike. I know how easy it is to lose track of how frequently one eats (although I've never had that experience before), but I hope that's the end of it, too. I'll pray for ya!

1. I wouldn't mind. I've been proven wrong twice now by expecting a repeat winner at some point in the 2nd or 3rd PMMCT (although Sunstar was already super close to winning a PMMCT already).
2. At least 2 months should pass, but no preference beyond that.
3. It was good, but I wouldn't change anything about it. The draw that PMMCT has to it is due to its simplicity in just showing up and voting. No need to add or take anything from that. The battle royale at the end was neat-o, but I wouldn't try to bracket too many of those throughout the tournament. It's easier to lose in a battle royale than a duel, and it might do some characters an injustice by pitting character A against an opponent that wipes the floor with the rest of the royale, then proceed to fight someone that character A might have actually been able to beat.
4. I've already PM'd you about this, but I think that you should only vote on the actual tie; voting on the other fights in the matchup is superfluous, especially because you have the chance of unnecessarily creating another tie by doing so. As far as you breaking the tie, I'm totally fine with that. It's only fair that you get an opinion at some point :P
5. 96. The more the merrier in PMMCT, both in voters and in competitors. I'd argue that 96 is more work than 64, but I don't think "more work" has ever stopped you before.
6. NOPE! Careful not to overcomplicate the simplicity of PMMCT in trying to improve the 4th over its predecessors.

Iunno what you're talkin about Mikey; I enjoyed PU...

Gemini Man. Personally, I don't get how Cut made it this far. He's an iconic RM, but he's far from my favorite.

I initially thought I was going to go for Sunstar hands-down, but after considering it, there's just something I like about Gemini Man. Might be a combination of the cool crystal-shard design and his cloning ability, but he just....stands out to me when compared to Sunstar. Maybe voting for a doomsday weapon would be too easy? Iunno.

Regardless, my vote goes to Gemini Man.

Quick Man. Both are great, but in terms of a RM overall, Quick Man is a cut above the rest. #notsorry
Gemini Man. I don't get the love for Enker, honestly. I mean, I love all MMKs, but Enker's my least favorite.
Vile. On paper, Sunstar is crazy cool, but as far as implementation and potential as a character? Vile. Vile by a long shot.

Megaman.EXE, actually.
Pharaoh Man. An endless stream of puns aren't the same as an Egyptian ruler.
Proto Mang. *begins to whistle*
Sigma. Enker's cool, but Sigma is really powerful and incredibly resilient (hey kinda like wahwie). If I was Mega Man X, there would come a point where I would start to completely lose hope just because Sigma kept coming back and threatening the world time and time again, no matter how many times I beat him.
Vile. There's just something about Vile I enjoy as a character over Ballade.
SCREW YOU GUYS I'M GOIN' RING MAN

Sunstar. I love Higsby, but Sunstar is just such a hidden gem.

Higsby."I may vote against [Zero] sometime down the road just due to the fact that other characters deserve a chance." Also, Higsby's pretty great.
Sunstar. If I voted Sunstar over Skull Man, Star Man isn't gonna change that.

Zero. I may vote against him sometime down the road just due to the fact that other characters deserve a chance, but not against Blizzard Man.
Higsby. There's just something super-lovable about Higsby as a character. Pitted against a lifeless character like Doc Robot, Higsby definitely outshines him.
Copy Robot. I've always kinda liked Copy in the sense that he's like Megaman's Dark Link, as opposed to a rival figure, which is Bass. I don't think he was meant to be like that until MMPU gave him a personality, but that's enough to set him apart from Star Man imo.
Sunstar. Sunstar is such a mysterious character that it's a pity he's never expanded on. Not only is he a doomsday weapon from space whose origin is vague at best (although I guess that's the case with most Stardroids), but he also exhibited a capacity for introspection and change that few of Megaman's robotic enemies show. And he's a doomsday weapon. I doubt there were plans to improve on Sunstar, and that's understandable. The intrigue, however, is enough to win him my vote.

Albert Wily. Obviously.
Ring Man. Everything I already said, plus, despite the fact I voted for him last round, I will admit that Metal Man gets too much spotlight.

So I got kinda ranty here and I'm not sure why...Bolded the votes as always, though, hope that helps.

Albert Wily I'm unfortunately not familiar with the Legends series, so I can't found a vote for Volnutt. However, even if I had, I still think I might vote for Wily. Gotta give the guy points: he's very tenacious and persistent to create so many bots and try several different approaches after getting his butt kicked so many times. Yea, he keeps throwing exactly 8 RMs at you, but he's stolen Gamma from under Light's nose, kidnapped Dr. Cossack's daughter, cloned a bot to look like Protoman, masterminded an artificial tournament, etc etc. He's a stubborn, old, and (don't forget) very evil coot, but even after death, Wily's mark on the world is one not soon forgotten.

Bass.EXE I like both Duo and Bass.EXE, and their designs are both awesome, but Bass.EXE played a much bigger part in his series. At the end of every game, when you think that you're the best around, Bass.EXE is always there to provide one more challenge, often facing him multiple times in one game, to prove that he is undoubtedly stronger than you are. It's a classic Bass dynamic, but in MMBN3, we see that Bass.EXE has a background and reason as to why he is who he is. It isn't deep or complex, but it doesn't need to be; it provides us with a moment of empathy and understanding that Duo simply doesn't have. Like, don't get me wrong, we understand the idea of justice, but that's all Duo is. He appeared for Power Battles and MM8 and that was really it; his background is "I'm from space and I fight for justice."

Metal Man I really do like Charge Man, but Metal Man is just so iconic. Apparently, he was the first bot built by Dr. Wily, and I feel like he just personifies the idea of combat robot so well. If it had been Charge Man vs. Shade Man, Charge Man would've won. Speaking of which...

Ring Man. Skull Man and Ring Man are two RMs created by Dr. Cossack specifically with combat in mind. Skull Man is very obvious in this regard for obvious reasons, obviously, and I like him and he's cool and he's great look at my avatar. However, I feel like Ring Man's merciless killer side doesn't get emphasized nearly as much (I mean, look at his stage, listen to his music). A vampire robot is a solid concept, and Shade Man's design isn't terrible either (although I don't love it), but Ring Man is not only a combat bot, but is made to destroy Mega Man, and having that sole purpose, since creation, and that drive to finish Rock is incredibly uncommon in most....."generational" (if you will) RMs in the Classic series. My vote goes to him.

Vile. Terra is neat in his own ways, but of the two, it's Vile that I'd be willing to shine a spotlight on. Sigma is very much a villain to all of the X series protagonists, but I've always felt that Vile is a much more personal nemesis to X, since Zero literally blew himself up to weaken him, and it was up to X to finish Vile off.

I just like story and character development, both intrinsically to one's own self and also his impact on others, and Vile has much more potential on that front than Terra imho.

Terra. You know how I said Roll started to grow on me? Kalinka has not.
Vile.

Terra. Really never understood people's fascination with Magma Dragoon outside of his SF moves.
Colonel.EXE. Essentially a better developed version of Colonel from the X series, both in design and story.
Auto. Guy doesn't get enough love.
Vile. Man, I wish they'd done more with Vile.

Ballade.

Rush doesn't deserve to go out like this, though...

Ballade. Why is this a question
Rush. Underrated and faithful companion of Mega Man who's fought alongside him even before Proto Man did.

Roll.EXE. I think Air Man is too overhyped, and Roll.EXE is given more personality than her Classic counterpart.
Ballade. Sure, Sage's design is neat, but a MMK is just...timeless.
Rush. Little guy doesn't get enough credit. Plus, you're pitting him against a MM6 fortress boss...
Roll. I can't speak for Tron Bonne because I've never played Legends :/. Plus, Roll's started to grow on me a bit since the comics. Just a bit, though...

Dark Man 4. I like Shadow Man, but I think Dark Man 4 isn't given enough credit.
Sigma. Wily's virus may have been his springboard, but Sigma has threatened the Earth on a couple of occasions; he's just overall more dangerous than Wily imo.

Punk. I believe I've already stated that he's my favorite MMK, although it's hard to not like any of the MMKs.