Good to hear that it is up and running again.
1) I wouldn't risk cleaning the case with anything other than luke warm water on a damp cloth.
2) As most of your TAM doesn't work at the moment, I can't see the harm that opening her up will do. It will be a good opportunity for someone to take pictures and actually produce a guide on how to actually open up one of these puppies. You might want to attempt cleaning the logic board contacts whilst you were at it, but I guess this will be a really daunting job.
3) Hook up an antenna to the radio socket and enjoy it. I currently do this on my TAM, whilst waiting for a PAL TV/Radio tuner to fall into my lap from the Apple Gods somewhere.
4) I'd recommend putting 9.1 onto the system and then use flash sticks to store your MP3 files on. I'm planning on putting a USB stick on the internal USB port in mine and using it as my jukebox storage area. Sticking an ethernet card in her is a good idea as then you will get internet (which is fun navigating in 800x600 and thousands of colours). Ethernet is also a lot faster than USB1.1 (groan).
Any pictures of her up and running?
I think I should get out my Canon and take some better shots of the TAM, as the one below looks pretty bad.