I haven't been to this site in 6 years and it's still an active community! Keep it up! This is going to get me fired up and back to breit's done. Taken a break for the kiddos but it may be time to teach the little ones how done.
Don't expect to get anything but gravity from honey if you boil it at all. I use US-05 for all my pale ales and IPAs with good results. Thats a prime temp to ferment it at too so I would expect many off flavors from it. It may just be a little young yet.
I would wait to use it until close to the end. Near boiling water will melt it really quick but <90 should help you speed up the temperature drop in the last few minutes.
I am assuming what you are describing is the cold break. Its normal. Depending on the recipe it can be really crazy at times, almost like a lava lamp. The goal is to chill the wort rapidly and get the cold break to settle and rack as little as possible to primary.
Glad to see the continued interest in the thread. I have to say though that I've moved on. As much fun as its been messing with this project someone finally gave me an old deep freeze so that what I'm using for my fermonator. It is 100x easier too. So for all of you that don't have the extra...