Hi James,

re:
> Question 3: related question: If I did create another cut-out there, is there a
> simple way to resize it (without removing it entirely and creating a new one)?

In v5 you can use the Transform > Move command on selected faces to edit openings.

Check out here for some demo screencaps:
http://moi3d.com/forum/index.php?webtag=MOI&msg=11803.1

- Michael