There is alot imbedded in your question. But I want to be as helpful as I can. So here are some general answers to your questions that might require some additional detail:
1) Best to file joint return.
2) No you don't need to change your health insurance.
3) It is generally a good idea to form a business (LLC, S Corp, C Corp) for a number of reasons. The only reason to NOT form a business would be cost to form and possibly costs to prepare and file a tax returns for certain business entities. The benefits most likely outweigh the costs. My personal opinion is operate your business a year or two (the "beta" years") while you prove up the business model, and then once you feel you have a viable business model and business, then you can step it up and form the business based on what you learned during your beta years and grow the business to great sucess!!
I hope this is helpful to you.
Kelly C.
CPA
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