1. Am I correct in thinking that even if a key logger got to the airgapped machine then if you never export anything from that machine other than the qr code for electrum then it is impossible to lose coins.
Not impossible, but highly unlikely. If you are executing anything other than the verified Electrum executable, then there is no guarantees.
2. With the issue with the warning and fees could be adapted to a much higher than expected amount. Does that mean that the worst damage would be the entire amount you are sending could be used as fees. Or worse that your wallet could be drained in fees?
Just whatever you are signing. You have to ensure that whatever you are signing is verified by you and that there is nothing out of the ordinary. A visual check of the transaction details will do. For example, if you are signing a transaction with two inputs, you should be sure about the amount that you're spending from the two inputs into your destination and change address. Anything that is not sent to those addresses are used as fees.
3. When you import the signed.txn back to the watching wallet would you not spot the increased fees before you broadcast or is there a reason you couldn't see that.
You will, but what is stopping the adversary from tampering with your transaction preview before you broadcast it?
While I can see in the air gapped address that the new change address is one of my own addresses I'm not worried.
However if it ran out of new addresses and made up a new one I could not see in there I would be concerned that is some hackers address. So can I do
a/ click the tool box icon in electrum when making the tx and uncheck use new change address. So that it will return funds to my own known address.
b/ go to the airgapped machine and do something to generate more addresses until I see that new change address appear.
You can. To do so, just increase the gap_limit from electrum console.
You should be referring to the receiving address, and not the change address in this case. Change addresses are generated and are automatically used in the transaction by the wallet.
I could put bitcoin core on the same machine as my electrum watch only machine. Do you mean there is in this case a way to connect the watch only wallet to send via core without putting electrum server between them. ?
You would still have to run an Electrum server.
This is very interesting to me. So I can take the signed.txn file via qr code and scan it with bitcoin core or maybe load the signed.txn and load it into bitcoin core and broadcast it?
Bitcoin Core doesn't accept .txn file. You would have to use Bitcoin Core console to do so.
For those accounts that a confirmed transactions can change recipient (probably not RBF-related, can you share one?),
Do you mean even the recipients address can be change with RBF until confirmed?
Confirmed transactions are unlikely to be changed, unless they have a competing transaction on another fork. In that case, the competing transaction must be in a longer chain. They can be replaced by another transaction, but it would require another signed transaction. The attacker can't do anything without a signed, valid transaction from you.
If you are sure you are sending enough fees then should RBF turned off for max security?
No.
I see that someone said once you spend from an address you actually lower the encryption from 256bit to 128bit.
Does that mean that every time you spend again and again it goes down further so next it is 64bit ?
Or was this person not correct in stating this ?
Incorrect. Security is not decreased by spending from an address.