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Flush if the breaker is going on a switch panel or a battery box lid where you want only the reset button showing. Surface if it lives out of sight and you would rather bolt it to a floor. The electrical side is identical; it is purely about where the body sits.
Enough for the body, the studs and a lug on each stud with cable bending away from them. Flush mounting hides the bulk behind the face, so check what is behind your panel before you cut. A breaker fouling a drawer runner is a discovery best made with a tape measure.
Usually not. A 60A breaker trips because the circuit is drawing close to 60A for long enough to heat it, or because something downstream is faulty. Check the load first, then the terminations, because a loose lug generates heat that trips a breaker doing nothing wrong.

AllSpark

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AllSpark

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AllSpark

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