Those are all great questions and I applaud you for researching before building. The toothpick will be used to put many multiple piece together in sequence. I have an amazing pair of clippers (somewhat like nail clippers except a bit different in shape). I saved them from multiple ROKR kits that include these for cutting apart acrylic pieces. They are WONDERFUL and cut them flat. You may still have to sand a bit afterwards. I find that waxing the picks make them go thru pieces easier…and I use a hammer quite often. As far as painting on this one, I painted in different sections AFTER they were put together as it is mostly raw edges of the wood. Sanding off the burrs will need to be done. I have done this one. Here is a link to it for viewing. Not ROKR The Dream Cabriolet @Jcm6864