I had my FFS surgery with Dr. Di Maggio in June this year. Overall, it went pretty well, but my forehead scar did not heal properly, so it stretched out and will require a revision. Regarding the other questions you mentioned:
1. The recovery was MUCH harder than I expected. My surgery lasted 10hrs and after they woke me up I wanted to die. Things got dramatically better after the first day though. I would HIGHLY recommend bringing someone with you to comfort you (just soothing words and to hold your hand).
2. Post-op care was okay. After 24 hrs in the hospital they'll encourage you to leave (although you can stay another night if you want). The hospital stay was mentally very difficult. The wifi didn't work and my tv remote died, so I felt very trapped. Also, they want you to have ice packs on your face, but it was very uncomfortable for me to be reclined, so the ice packs kept falling off my face.
3. In the hospital, they were constantly asking if I was in any pain, but it was never overly painful, just extremely uncomfortable. Once out of the hospital, they will give you Toradol pain pills. This took care of the pain adequately, but after taking them for over a week, they upset my stomach.
4. After surgery, my scalp, chin, and nose were 100% numb. My lips were partially numb. Three months later, my chin is still partially numb, my nose is mostly okay, my lips are normal, and my scalp is still mostly numb. From what I've heard, this is normal.
5. If you're going alone (which I don't recommend), stock up on food and supplies before your surgery. For the first few days I was on a liquid only diet. So I recommend bringing a can of protein shake mix and buying the instant soup mix. Having straws is very handy during this time. Also, be sure to purchase Kleenex. After the first few days, it's soft food only (pasta is nice).