I'm not aware of a concrete overall vertex limit, but performance will suffer eventually. Try to stay close to what the original models use, this will both help keep things smooth and improve visual cohesion with the base game.
Typically, caps are hidden until dismemberment. But I'm not sure if that's hardcoded, or if models explicitly mark these cap surfaces as initially disabled. If it's the latter, you should be able to have caps that start on. Or just don't give them the magic cap names, just make them "regular" always-on surfaces. Having a cap that doesn't behave like one would probably just be confusing to anyone examining the model.