Welcome to the board!
The thing is, pretty much all of your questions have been covered in depth in the tacked threads at the top of each subforum and in the posts availble through the search function. Thus, everyone is pretty much going to tell you to search for answers before re-asking previously covered questions. That said, I'm going to do a quick rundown of my personal opinion-based answers to your questions, since I'm in a good mood today
1. I bought, many build, this depends on whether you want it NOW or are the kind of person who would be much more satisfied putting it together yourself. Also remember, you could buy a complete upper and build the lower, which is what many first-timers do.
2. If upper/lower separate makes it cheaper, go that way (especially if you're not a safe-queen matching-finished-obsessed kinda guy).
3. 20" = longer "hyper-lethal" fragmentation distance, due to higher velocity. 16" = better handling (IMHO). You decide.
4. All the crap that you hang on your uber-cool rails and your holding of the handguard won't effect POI. The effect is negligible on a combat carbine, but probably a good idea for a precision rifle.
5. Standard fixed = sturdier, flip up you can flip down out of the way of your optic. KISS guys will go with fixed, guys with 1x optics (EOTech or Aimpoint, etc) tend to like flip downs. A high power scope will not be obscured by the FSB.
6. You probably mean chrome-moly vs. chrome-lined chrome-moly vs stainless. Stainless = more expensive, most corrosion resistant, shiny (unless refinished/bead-blasted/etc). Chrome lined makes the chrome-moly steel more corrosion-resistant, but can have a slight negative effect on accuracy (I'd go with chrome-lined on anything more mobile than a bench-rest gun).
7. Hesse is pretty much universally reviled. You will hear people bash Olympic Arms, DPMS, and Model 1 sales, but it seems like YMMV. I have no OlyArms experience, Model 1 sales seems to have some QC issues but overall not too bad, and DPMS, well, some people just have it in for DPMS. My DPMS carbine rocks, so who knows.
8. Whatever works for you
9. Vortex and Phantom are probably the two most popular, next to the A2