This game is super fun, have a few questions:

1. Minimum/Maximum Deck Size?
2. Maximum copies of a card per deck?
3. Multiple factions per deck?
4. When Warlord returns to HQ does he heal?
5. Does the deploy phase operate like this? I deploy a card, allow my opponent to deploy a card which he does, then he passes and lets me deploy, etc etc. Or only one chance to deploy then pass, then next phase?

1-3: Rather than answering these directly, I'm going to direct you to pp. 15-16 of the Learn to Play guide. Because of the warlord's signature squad and the "loyal" icon, deck construction is a little more involved than the answers to these three questions.

4: No.

5: The Deploy Phase goes like this:

A. Player with initiative deploys a card or triggers an action.

B. Player without initiative deploys a card or triggers an action.

C. Repeat A-B.

Once a player passes in A or B, they cannot deploy any more cards or trigger any more actions that phase. The phase doesn't end until both players have passed.

For a full, detailed description, take a look at p. 23 of the Rules Reference Guide .