My preference would be to put the additional stuff into another database & live with the dependency.

I would, however, make sure that this was a one-way dependency...

Are you using a Fixed Width flat file destination in SSIS? You should be able to define all of your column widths there, without the need for any fancy REPLICATE...

This is possible and does not require any scripting, just a technique known as 'recordset shredding'. Take a read here, if you'd like to know more.
It assigns...

OK, but what's your question?
Are you asking us to modify that huge proc for you?
The people replying here do so for free, in their own time,...

You know it's a Friday when a general office announcement e-mail is sent out and everyone hits Reply To All to send congratulations.
Humbug.