Gosh, Ben Danger, I love how enthusiastic this thread can get. But I don't think I understand any of your ideas.

There is no need to have Maul get torn apart in episode I and then torn apart again in episode II. He is simply being rebuilt into Grevious somewhere in the background of episode II until he is somehow revealed.

It would presumably be at this point, when Grevious is unveiled, that he is given the alias of "Grevious" and the title/rank of "General" for his work among the separatists. He need not have ever been a general before.

I can't understand the impulse to hide Christopher Lee's priceless face. He is Jedi Count Dukoo and presents himself as someone with an official capacity-- he pretends to be offended that Obi Wan has been captured. All of this will come off strangely if he wears a mask. What Jedi's wear masks?

The entire "sifo-dias" matter in SOTDS is moot-- the name has been cut. (Hopefully it will be changed even further if we can get the material worked out to replace "sifo-dias" with "Qui Gonn".)