1" mdf
#4
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have you checked home depot/lowes? if they dont have any ask there where you could find some, they DO make it, its usualy a commercial material (used for commercial businesses)
#7
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i looked there i did not see anything. has anyone bought the videos they have for sale or seen them. i am seriously thinking of buyibg the series
#9
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3/4" is strong enough for any man. Saves some weight, also. The key element in a strong system is the joints. Predrill, use lots of screws, and glue the heck outta it. Make sure the edges will fit nicely. It'* all in the joints.