Hello SubterminalOptimization. I like your name very much.
To answer some of your questions:
Your premise is correct. The goal is to complete the game on Dominating with 0 deaths/reloads. Obviously breaks will be included since I have to work, cook, lift, spend time with loved ones etc.
I didn't want to use quick tinkering because I think it is OP and this is a challenge run. IMHO quick tinkering is the single most powerful defensive feat in the game, and it doesn't take much investment. Quick tinkering actually does help with doppelgangers, when they step on a bear trap they lose all movement/action points for the turn (unless this has been changed, I haven't used quick tinkering in forever since I think it's OP).
To answer about aimed shot I want the option to have a sniper rifle in slot and delete a target before the battle starts. Since I am on ironman both planning and flexibility are very important. Also as far as skills, I only meant what I had maxed up to this point. At some point I will most likely be funneling points out of throwing, stealth, hacking, and lockpicking and pumping biology & chemistry to cover against certain hazards, some of which you've mentioned. Mental breakdown / incaps? solved with 80 bio. mobbed by death crawlers? irongut. As you've already pointed out, many gaps can be bridged through the use of crafting.
While I want my playthrough to be as certain as possible that does not mean I am going to avoid fights I can lose. In my opinion that is part of the fun of it

.
Guns are most likely not optimal since psi is OP and can't miss, but I'm not a fan of psi and armor piercing bullets are extremely powerful.
You're definitely right that the most hurdles will be found in deep caverns so maybe when I get an iron man run close enough to that point I will use another of my chars to do some testing and practice in there before I head down.
I found your idea for a challenge run to be interesting as well, to minimize the requirements to complete the game. How did you get this idea? Was it from speedrunning? Do you plan on attempting a speedrun at some point?