A lot of useful info here.
http://www.easy2boot.com/ if you want a massive multiboot. I think it is based on grub4dos so you could actually use it.
No, a usb flash or hard drive doesn't need a mbr. There are basically three ways. MBR. Compatible mbr/uefi and gpt.
Iso images are not created the same. There is so much variation in how they are made and meant to be use that no one single method can be used usually. Simple dd or 7z commands can create a lot of them. You already know that creators exist for some that work great for single use.
Only needs to be active if you have more than one partition usually. (some OS's may require this)
Starting with a system group you may find it easier to create usb's.