: 1. BWCA requires permits, which you can apply for ahead of time and on-line,
: but have to pick up at a ranger station (most likely Grand Marais).

You can also pick them up the day before you head in. There's always an entry point open if you're flexible. It might not be your first choice.

: 2. if you go into Quetico,

It's now $20/person/night for the Q from the American entry points. Less expensive from the Canadian side.

: you will need either a passport or the Canadian
: remote area access pass which you have to apply for early by mail, but I'm
: not sure what is required now - given the border entry changes etc.

No passports are required and the earliest that they could be required is June 2009 from the American side. The Canadian side, as far as I know, doesn't have anything on the books or have any plans to put anything on the books to require Americans or Canadians to use passports to cross.

: 3. July is prime bug season, so be prepared and the lake(s) can be heavily
: fished with a lot of competition for camp sites.

I generally find June worse for bugs and July can definately be bad, but the black flies of June are usually gone by July. Still, bring headnets!!!!! And a Tundra Tarp if you have one will be nice for after the sun goes down.