You're right. The Imperial medical scientists of Galactic Empire could have done better for him. They have droids after all. Consider him 90% dead and on life support in his armour.
yes they would. he's still hot just put his helmet on. also the look doesn't have to be the final look. you are breeding for ultimate sith power with vader so looks don't matter esp. if you have a fat ugly guy with hot girl fetish.