[acidrain]

OK, yes you have your acid ratio correct... add an additional 64 oz. of water to what you already have.
You can ano below 4.5 amps/sq. ft., but it will be in the tank an awfully long time. I would step up to a bigger PS myself. It will make a stronger, more dense pore structure if you do.
You can heat the dye on the stove, or in the microwave if the dye batch is small. I use a double boiler system... I keep the dyes in 2 gal buckets, and simply place the entire bucket in a large canning pot with about 4 inches of boiling water in it. Get yourself a digital thermometer (less than $10 at a lot of places). You'll need it for all the steps.
I don't know if I asked this yet... do you have good agitation?
Besides monitoring the temp of the ano bath, you have to have good agitation so that the bubbles are knocked off, but more imortant, so that the thin layer of acid next to the part remains at the lower temp. as well.
Finally, I suspect the dye is fine, but you'll need to keep at the test pieces to know for sure. The color of the dye can be decieving, but as I recall, the yellow dyes look really yellow in the bucket. Somebody else here got the wrong color, but I can't recall what the color was.