Richie:
See below -
1. Is there a preferred sequence for gluing up the panels ? The directions seem to suggest that a front and rear panel be first glued to each side wall, but it almost seems like all the front and rear panels should be glued together first and then the side walls.
I have built long structures both ways. It ends up what you feel most comfortable with. With a side wall glued to a front or rear panel you end up gluing the remainder with the walls standing up. If you glue the sections (front, back, sides etc) as a unit then you are gluing them flat on your work service. I prefer this method since among other things it allows me to glue supports and spacers to the inside of the walls and use weights to hold until the glue sets. Just make sure the instructions are not saying what order for a specific reason (maybe fit).
2. Are the vertical uprights at each end of the wooden beams supposed to butt right up against the front and real panels or are the ends of the top beams supposed to butt up against the panels ?
I have never built this kit so don't know. My assumption is that if you are building the internal wood frame as a standalone unit you want some space between the uprights and the walls. if your intent is to make the walls and wood frame one unit then glue them to the walls. If this is your intent just make sure what ever supports you glued onto the walls in the first place don't interfere with placement of the wood superstructure.
3. Is there a preferred material to use for flooring and would it make sense to install the floor as one large panel and then trace and cut out from the bottom where each individual track is going to go (rather than cutting a section at a time on each side of the tracks) ?
Flooring is basically your choice from a whole bunch of different methods from plain hardboard to scribed wood sheets. With hardboard yea you could use one panel, trace out the track and cut it into pieces. For scribed wood the best I have seen is 8 inches wide so you would be working with several pieces.
4. It looks like some people are using Plastruct lamps with LED's. Is there a newer/better method of lighting the RH, possibly using LED strips with built-in resistors ?
There are Woodland Scenic lamps though I think you are talking about interior hanging industrial style lamps. For this I use Plastruct. See attached file. However be aware of the LED lights you buy. Those that come with built in resistors will not fit through the tubing. If you use LED you will have to purchase those without resistors and attach your own after the lamp is in the tubing.
