1. The grooves in the cutting table can be done with a router if your table saw won't do, other than that, you can either make holes with T nuts inserted from the underside, or do like i did and use some grooved slot wall MDF, or at least i think that's what it's called, take a look: http://www.cnczone.com/forums/attach...8&d=1177735329
2. I'm thinking it's possible if you design it right, but i'd advise caution cause i wouldn't be comfortable with it for myself doing it.
3. This i think would be a matter of choice for you, but my advise for the best buy for your budgeting dollar would be the hobbycnc kit as long as you have no objection to soldering your own board, it's a great kit that has everything except for the transformer, great documentation and a fantastic support group.
4. I'm not too sure if you are fully familiar with using this forum since i see you are creating a number of new threads lately, you might be clicking on "New Thread" by mistake, try this: