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Additionally, I would agree that 9% Honey malt is way too much, especially for an American PA

Looks like default in BeerSmith is Tinseth. In my experience, IBU's in Tinseth are generally lower than others (Jamil Zainasheff uses Rager for ex), especially for late hop additions. Rager gives you 39.7 IBU Tinseth: 28.6 I'd say thats definitely acceptable for an APA

I've never had a problem mixing in while on the heat source. If you stir the crap out of it, there is a low risk of scorching

Which IBU method did you use?

Maybe get a brew belt?

I would say fermentation temp control

How would you categorize New Belgium 1554? To me probably most similar to a dark american brown ale or a robust porter. TastyBrew.com calculator lists those styles with average volumes: American Brown - 1.5 - 2.5 Robust Porter - 1.8 - 2.5

According to TastyBrew.com's priming calculator, 1.75 Volumes CO2 would require 2oz Corn Sugar for 4 Gal @ 70F. So I think your measurements are correct.

How does the presence of yeast on the bottom of the vessel discourage more yeast from dropping out? This might sound like a smartass question, but I assure you, I am legitimately asking.

Not sure if its the curse, but my second batch "finished" out at 1022, only to explode 4 times in my closet. You can probably bottle it and watch them like a hawk. If they get a bit over-carbonated then just throw them in the fridge

Do whatever you like. My first 3 AG batches were 3-3.5 gallons, because like you, I didn't have a large enough pot. The problem was that I didn't create enough beer. Now I'm back to 5 gal batches :)

Just get one. Its only $40.

+1. I actually just let it sit for at least a month. No point in taking gravity until then

Never had that problem, listening to an old Sunday Session right now

i don't even drip dry, I just take it out of the sanitizing bucket and fill. absolutely no problems with that

Same here. I just rinse before using, because my dishwasher tends to leave a bit of soap on my dishes

Yeah, that one is a little tougher, but glad you didn't have to kick her out

I use this calculator: http://www.tastybrew.com/calculators/priming.html

Interesting.. My wife loves the smell of brewing beer. Brew outside

There are no issues with only using a primary. I never use a secondary, and neither do lots of folks here