1. 1/32 microstepping:
* Not with the built-in drivers, they're allegros and only go down to 1/16.
* 0.9 degree stepper works well, but remember they're larger and heavier for the same torque rating, so expect some additional mass!
* I understand an external stepper driver may seem daunting, but maybe keep it in mind for the future as you learn more. Probably the cheapest way is to use a DRV8825 pololu module, and make up a daughter board for it (using prototyping board). If you research the connections to the pololu module, what they do, and find the step/direction/enable outputs on the smoothieboard, it will start to make sense...
Otherwise, for a cost, there are packaged stepper-driver modules on eBay - you want 2A+ current, and at least 32X microstepping, but expect this to be $30 instead of $5.
2. No soldering:
* 5XC comes with most of the connectors already soldered in, I think it would be enough to get started at least. I soldered my own (5X), but the heat-management of the pads is so good it's actually quite a pain to DIY. If you want to add something like a breakout board for external stepper driver, then you'll likely need to solder in a few headers yourself.
* Again, don't be afraid of soldering. You need three tools: a plug-in mains soldering iron ($20), a reel of regular ordinary solder ($5) and one of those solder-sucker tools ($5-$10), and you're on the way to learning a whole new extremely useful skill! Practice on less expensive boards first (a small kit from the electronics shop while you're there is often a good start, and there will be a million youtube videos on the practice of soldering...).
3. AC bed connection:
* Using the mosfet output to control the SSR works fine. Match up + and - on the output and the relay and it will work fine. The only downside is it's a bit of a waste of a power mosfet!
* It's pretty easy to change the pin in smoothie config, so you might prefer to do this too. Up to you!
4. Fan config:
* Yup - all sorts of ways! You can create a 'switch' in smoothie config that does anything, with any gcode you like. For a fan like you suggest, you can create a switch that turns the fan on and off with spare m-codes, and add these to your start/end gcode in slicer / cura etc. I think they can even do PWM without much effort - just copy the default config's definition for the nozzle fan! For an actively-cooled hotend, there's also a "temperatureswitch" which can turn the fan on and off automatically based on the hotend temperature.
* Have a read through this: http://smoothieware.org/configuration-options
* Have a read through the example config file, this helps the above make more sense: https://github.com/Smoothieware/Smoothi … ard/config
SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi