I was considering doing a chat server using node.js/socket.io. Should I make it a tcp server or a http server? I'd imagine tcp server would be more efficient, but can you send other stuff to it like file attachments etc? If tcp is more efficient, how much more so? Also, just wondering how many concurrent connections can one node.js server handle? Is it more work to do TCP or HTTP?
You are talking about 2 totally different approaches here - TCP is a transport layer protocol and HTTP is an application layer protocol. HTTP (usually) operates over TCP, so whichever option you choose, it will still be operating over TCP.
The efficiency question is sort of a moot point, because you are talking about different OSI layers. If you went for raw TCP sockets, your solution would probably be more efficient - in bandwidth at least - since HTTP contains a whole bunch of extra data (the headers) that would likely be irrelevant to your purposes (depending on the scale of the chat program). What you are talking about developing there is your own application layer protocol.
You can send anything you like over TCP - after all HTTP can send attachments, and that operates over TCP. FTP also operates over TCP, and that is designed purely for transferring "attachments". In order to do this, you would need to write your protocol so that it was able to tell the remote party that the following data was a file, then send the file data, then tell the remote party that the transfer is complete. Implementations of this are many and varied (the HTTP approach is completely different from the FTP approach) and your options are pretty much infinite.
I don't know for sure about the node.js connection limit, but I can say with a fair amount of confidence that it is limited by the operating system. This might help you get to grips with the answer to that question.
It is debatable whether it is more work to do it with TCP or HTTP - it's a lot of work to do it in both. I would probably lean more toward the TCP option being your best bet. While TCP would require you to design a protocol rather than/as well as an application, HTTP is not particularly suited to live, 2-way app