How do I integrate a 5 channel looper with a mixer with 2 Aux Sends/Returns?

I have access to the following gear and not sure how to connect it all up to use with the 5 channel looper? I’m new to using a mixer so assume I know nothing, or even worse as I know a little bit which can be dangerous! 
1. Keyboards, guitars, microphones, ipad, PC (Input only)
2. Boss RC-505 Loop Station (Input/Output)
3. Behringer X1622USB Mixer. https://www.behringer.com/behringer/pro ... Code=P0A0J
4. Boss BCB-60 Pedal Board and about a dozen pedals. Used with the 2 Aux Sends/Returns as I will have some in the board and some in a loose chain.
I have two questions:
1. How do I setup the mixer so that I can record from a single input channel to the looper using the two Aux sends/return, whilst all the other channel inputs are active?
2. Do I need to use hardware device(s), DI box etc, to match the signals between the mixer I/O and the two pedal chains? Or can I just use the Aux Send/Return levels to do that?
First.
For example, I want to record a guitar being input to CH1 on the mixer to the looper whilst monitoring any other inputs to the mixer which will include the output from the looper which has 5 channels; including the one I am recording to. This whilst using the dual Aux Sends/Returns on CH1 only, so that the effects are added to the guitar that is recorded to the looper.
My first thought is to only have the guitar on the main mix buss and send everything else to the SUB buss.
1. If I do that, do I lose the ability to add EQ etc to all the other inputs? Not sure if the channels are routed to the SUB buss ‘pre or post’ if that is the correct usage of those terms? I won’t be using effects on the other input channels even if the routing allows as I need to leave them free for the guitar only.
2. When not recording to the Looper, everything goes though the main buss and I monitor in the standard way. But when I am recording loops and sending everything except for CH1 to the SUB buss, I have to monitor via the SUB buss only.
As this buss seemingly is only output on the back panel via the two labelled SUB 1 and 2, I can’t monitor via the headphones in Loop Record Mode. Plus my final physical outputs will be different depending on whether I am Loop Record Mode or not.
So is the only way around this to send the outputs from both the main and SUB busses to a second small mixer? With that mixer I just use the appropriate input depending on if I am in Loop Record Mode or not and the headphone output will always give the correct signal.
Any suggestions for a very small mixer with two stereo inputs and a headphone output? I have access to a Yamaha SC-02 but that is battery operated so probably not ideal.
3. It’s important to have the ability to monitor via headphones as well as via external speakers at all times.
Second.
Both the Mono Mic input channels and the stereo input channels accept a wide range of input levels.
The stereo input can be switched between +4/-10 and the mono line input has a gain control rated for +10 to -40dB.
1. So do I require a DI box when plugging a guitar into either of these? I am more likely to want to use the mono mic/instrument channels but good to know if I can use either. Having one less box and cable is good.
2. The Boss BCB-60 Pedal Board presumably has a guitar level I/O signal. So how do I match that with the Main Aux Sends/Returns on the mixer? Can I just adjust the Aux Sends/Returns I/O levels to match or will I require a DI Box for the returns and something else for the sends to attenuate the hot signal?
My brain is rather fuzzy these days and this is new to me so please point out any glaring errors and also omissions as maybe there are some techniques that will give me more choices.
I’m happy to experiment and will be very careful with levels so if doing that am I unlikely to damage anything?
I want to get an overview of what is possible before deciding on what cabling and DI boxes etc to order. Thanks.

1. Keyboards, guitars, microphones, ipad, PC (Input only)
2. Boss RC-505 Loop Station (Input/Output)
3. Behringer X1622USB Mixer. https://www.behringer.com/behringer/pro ... Code=P0A0J
4. Boss BCB-60 Pedal Board and about a dozen pedals. Used with the 2 Aux Sends/Returns as I will have some in the board and some in a loose chain.
I have two questions:
1. How do I setup the mixer so that I can record from a single input channel to the looper using the two Aux sends/return, whilst all the other channel inputs are active?
2. Do I need to use hardware device(s), DI box etc, to match the signals between the mixer I/O and the two pedal chains? Or can I just use the Aux Send/Return levels to do that?
First.
For example, I want to record a guitar being input to CH1 on the mixer to the looper whilst monitoring any other inputs to the mixer which will include the output from the looper which has 5 channels; including the one I am recording to. This whilst using the dual Aux Sends/Returns on CH1 only, so that the effects are added to the guitar that is recorded to the looper.
My first thought is to only have the guitar on the main mix buss and send everything else to the SUB buss.
1. If I do that, do I lose the ability to add EQ etc to all the other inputs? Not sure if the channels are routed to the SUB buss ‘pre or post’ if that is the correct usage of those terms? I won’t be using effects on the other input channels even if the routing allows as I need to leave them free for the guitar only.
2. When not recording to the Looper, everything goes though the main buss and I monitor in the standard way. But when I am recording loops and sending everything except for CH1 to the SUB buss, I have to monitor via the SUB buss only.
As this buss seemingly is only output on the back panel via the two labelled SUB 1 and 2, I can’t monitor via the headphones in Loop Record Mode. Plus my final physical outputs will be different depending on whether I am Loop Record Mode or not.
So is the only way around this to send the outputs from both the main and SUB busses to a second small mixer? With that mixer I just use the appropriate input depending on if I am in Loop Record Mode or not and the headphone output will always give the correct signal.
Any suggestions for a very small mixer with two stereo inputs and a headphone output? I have access to a Yamaha SC-02 but that is battery operated so probably not ideal.
3. It’s important to have the ability to monitor via headphones as well as via external speakers at all times.
Second.
Both the Mono Mic input channels and the stereo input channels accept a wide range of input levels.
The stereo input can be switched between +4/-10 and the mono line input has a gain control rated for +10 to -40dB.
1. So do I require a DI box when plugging a guitar into either of these? I am more likely to want to use the mono mic/instrument channels but good to know if I can use either. Having one less box and cable is good.
2. The Boss BCB-60 Pedal Board presumably has a guitar level I/O signal. So how do I match that with the Main Aux Sends/Returns on the mixer? Can I just adjust the Aux Sends/Returns I/O levels to match or will I require a DI Box for the returns and something else for the sends to attenuate the hot signal?
My brain is rather fuzzy these days and this is new to me so please point out any glaring errors and also omissions as maybe there are some techniques that will give me more choices.
I’m happy to experiment and will be very careful with levels so if doing that am I unlikely to damage anything?
I want to get an overview of what is possible before deciding on what cabling and DI boxes etc to order. Thanks.