You got questions, I got some answers:
The Melamin I used is particle board, however I have seen no problems with heating my platens. The biggest problem I can see would be with moisture, but if the cut edges are sealed that should be no problem.
If the screen is properly glued, there should be no effect on tension when attaching the tuners. The holes through the edges of the mesh are only 1/8 inch in diameter and 3.8 of an inch from the outside of the frame. There's enough material glued down between the edge of the print area and the tuner that the screen tension shouldn't change at all.
If you have decent screens you should have no issue doing process printing on this set up. Heck, like I said on the video, I've seen it done on a Yudu (check out TYGERON's stuff) and this setup holds extremely tight registration.
Gilligan and Tygeron, short versions of video will be out this weekend.