1) NO not all gas tubes are fluted. Those that aren't are usually on the AK derivatives, such as the Valmet/Galil models. They use a larger collar to compensate for the lack of ribs.
You could EASILY build your own non-ribbed gas tube from some 4130 tubing of the proper diameter and wall thickness. I've build several for my custom builds. Look at AIRCRAFTSPRUCE.COM for 4130 tubing
The need for ribs vs. non-ribbed is simple - the ribs are sized so that a certain amount of gas escapes during the venting cycle. Without that, you can use the larger-ringed piston, but you will find you may be over-gassed and will have to drill bleed holes (like on Chinese AKs and Galil tubes) to compensate. Too few bleed holes = violent cycle, harder kick; too many bleed holes = potential for short-cycling in cold or dirty conditions.
THe back locking points can be easily made by cutting the tube long, cutting about 1/4" off of the sides, and bending the "tabs" up and down to get it locked in place when fully assembled.
2) hand guard tabs? As in the rear extension? That sits inside the receiver underneath the barrel. If you're finding that with mixed parts, you may need to reshape the "tab" to fit without prying.
3) A little side-to-side rattle is considered acceptable by factory armory standards. Front-to-back is not. So I've read. You can usually tweak the parts with some pliers and creative thinking to take up slack enough to limit rattle.