Major issue was that fullscreen wasn't working on 10.7.
Can't say I noticed that (I did notice some "sparkling" on exit, there'd be a delay between exiting the game and the desktop reappearing where the screen would be black save from some minor pixel noise, but nothing really major), but I can't say I was really looking that hard...
Yeh, I'm not sure about 64bit on Mac (*nix underneath) being as easy as flicking a switch in Xcode. I've heard on the forums here that one or two has got 64 compile working, but I've never reviewed an Xcode project file that I could use to do the same.
Funny thing is, I'm pretty sure that's all it is. You change "32-bit Intel" in the "Architectures" section of the project for each target (I get the idea it's supposed be a "set once, update everwhere" type deal, but that has never worked reliably in any of the projects I've opened in it...) to "Standard 32/64-bit Intel" and that seems to be it.
Beyond that, you also need x86/x86_64 compiled versions of the dependent frameworks, but I've already taken care of that if you want to save yourself the trouble of compiling them yourself. I'm wondering if this is why you didn't change it when you were modifying the Xcode project files for r8671:
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r8671 | Echelon9 | 2012-04-15 14:20:56 +0800 (Sun, 15 Apr 2012) | 1 line
Ensure that the Xcode 4 project file can build Mac binaries for OS X 10.6, as well as 10.7
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Anyway, I have some builds I could throw out for testing if you'd like. I can't offer any support for them myself, so I won't throw them out there if you won't be able or don't want to handle any additional support queries related to them.