Thank you Shipnil and Ravi, thought to provide an update post the trip here, this may be relevant for some more days at least..
Bangalore to Tirumala:
1. Roads are in good shape all through, as reported by others - 4 lanes till little beyond Mulbagal BP I guess, there is a toll booth in construction beyond which its single carriageway towards Tirupati
2. two diversions at 6 and 8.5 kms from Chittor bypass towards tirupati, well laid, doesnt seem to get crowded/bad during traffic
3. One place little beyond, where the traffic is diverted to opposite side lane for a few hundred meters, wasnt bad for me while I was driving early morning hours
4. Good signs and marking all through the roads in KA
5. Entering a town close to chittor BP, where I found two speed breakers not marked, not able to recollect, starting with 'P' I guess, but you can make out that stretch when you see the bollards with reflectors on both the sides for few hundred meters
6. It was dark in the return journey as well with more traffic than early morning we had. Almost all the vehicles on single carriageway were driving with high beams ON, private busses and TTs were horrible when they overtake, they won't bother if they have enough space and time for the maneuver, they would just do it, so keep your calm on this stretch and drive safe
Around Tirumala:
1. My Buddhist prayer flag was famous around the security check, I was stopped twice and asked to take it off, spent a few minutes to convince them and finally told them that its not anti-hindu, something to do with Hindu mantra only
2. Security check may take a few minutes depending on the rush, they will get most of the luggage thru the scanners, good we were not carrying any. The toll ticket given here will be checked while you entre Tirumala and when you exit Tirumala and again at foothills. During the exit, the person would suggest you to go slow for this 40 minutes route down hills (uphill it seems to be about 28/30 minutes, should be smaller route I guess). At the foothill when he scanned the toll ticket, I remember seeing the display telling me that I reported early by 7 minutes

3. Roads in Tirumala are well marked on maps and good signboards as well, those small green signboards bit difficult to read even at slow speed though
Darshan:
1. We went straight to Vaikuntham-II, this is opposite to Museum where the senior citizens are picked up in a golf cart and taken to the place where the queue starts, should be around 500 meters
2. Ample parking space in the surroundings here, we heard from others its more than usual crowd for past 2-3 days, not sure if that’s the effect of exams schedules coming to an end
3. Sr citizen timings on the website as we read were, 10AM and 2PM. We were late when we started from home so could only make it to tirupati foothills by 8.30AM which was the time we were supposed to be at reporting place
4. Got to the place where queue starts by around 9.30AM and got into the queue which wasn’t that long, got my grandma to sit/take rest while we save her place in the queue, unfortunately, they stopped taking people in exactly at 9.50, so here the 10AM slot got full, I guess they take around 700 people for this sr citizen slot; asked us to wait till 12/1 when they start next slot for 3PM darshan
5. So, for 10AM slot, they will start taking people in about 2 hours before the slot time and just a few minutes before or if the slot is full, they will close the slot
6. My grandma got in first with my wife as attendant, my father/mother were not allowed here, my father is 64 and mother is 61, we came out quietly and thought of exploring the free darshan slots, but it seemed they will just give you a slot timing sometime in the night, so we decided not to go for it, they already had darshan a few years back when they travelled on a package tour
7. My grandma/wife had to wait there till 2.50PM when they opened the Darshan for 3PM slot, they were provided with some refreshment/milk/food etc while they were waiting in the hall
8. They spent some good time during and post darshan around the hall and came out at around 3.45, I got into the queue for Sree vari laddus, so far I was at ease for hours, exploring the surroundings, kindle book and tea shop kept me entertained, but the 45 minutes I spent trying to get these laddus were horrific, people were jumping from one counter to another, not knowing which counter is operational/serving, some of them were consistently serving and had long queue, one such jump worked for me and got to a counter that just opened and got the laddus in a few minutes time