Zeke,
Q2 - Look at Model Railroader Aug 2012 PG 54 for an article on tip a switch machine on its side. This should help with actuating the turnout.
Q3 - See my blog the Ron linked.
Q4 - there are some diamond cut-off disk with small diameter and thin profile that should help here
Bill your layout is Awesome!
Does the Boeing Employee MRR Club in St.Louis have a website?
I visited the BEMRR club in Kent, Wa. last May while I was in Seattle area.
From another Boeing Employee in Texas