I skip that 1.
2. I have made a guide to spraypainting. Okay, I painted my pärrä, which means motorbike here in Finland, but same technique can be used when painting console cases. Guide is written finnish, so use that $#!tty Google Translate to understand it. There is some strange words and sentences in there, but feel free to ask if you don´t understand something
3. I think that Dremel is the best tool you can get. a) You can get shapes and arts with different Dremel tool ie. sharp tip. b) For cutting window, you can use those disc blade tools for Dremel. After that, sand those cutted edges to smooth using file and sandpaper. For windows, I use Macroclear Polycarbonate plex to my case windows.
4. Hmm stencils. I don´t know about that. I always made my own using very different materials (paper, cardboard etc).
lol forgot link to that guide.... http://www.xhackerbox.com/keskustelualue/viewtopic.php?f=29&t=3804