Gapping
What are some disadvantages of gapping too tight (other than stalling)? Also, do you know if they have a stock standard of gapping at the factory or is all just arbitrary?
Factories do have gapping standards, though instruments will vary individually.
Optimal gapping will deliver maximum performance for minimal input. But as you know, gap too low and reeds wil stall. Gap too high and they will take too much breath flow to start. So where do manufacturers locate their optimal gapping within these boundaries?
They set "standards" (parameters) partly based on reed performance, and partly on the expected behavior of the average buyer/player.
Low-pitched reeds, especially ones with weighted ends, are gapped higher because more breath volume is needed to budge the larger mass of the reed. As a result, a heavy reed will stall at a gap that might be fine for a lighter reed, and a very light reed can be gapped much lower.
Stock harps are often gapped a bit high also because beginning players may use to much breath force or generate mouth pressure or suction that will make reeds stall, squeal, or pre-bend. Higher gapping can help reduce (though not eliminate) these problems, which often lead a beginner to blame the harp and demand a refund or exchange.
The often stated rule of thumb is that the gap at the tip of a reed should be abut the same as the thickness of the reed tip. This will vary, partly for reasons mentioned above, and partly because individual players will have different breathing approaches and different technical objectives (such as overbending).
I guess you answered the first question already in the Ask David Barrett forum but I was curious about the second question if you know the answer.