Hi George,
Sorry, quick reply as it is a bit late, I'll take photos tomorrow to answer your questions.
Basically, don't worry about the holes in T1, this is only to pass your servo cables, that have no other functions.
In green, yes, don't glue! Use screws, as this will allow you to unscrew the servo tray if you need to do a bit of maintenance.
I feel your pain for the tubes / rod... My tube was 7mm inside, and had 8mm rods! :!: :!: Sanding, re-drilling of the tube etc etc :!: :!: :!: