I know I can answer two of your questions.

First 2 inch sides are enough. Some people don't even use coroplast with fleece bedding. Me being one of them, I only have towels, fleece, then floor. They don't really kick out stuff as much as rats or some other small animals, so the only worry is it going through to the floor, but I clean the cage often, plus the pigs have sorta potty train themselves to only go in the bedding sections I have in the cage. Also for your second level question. The best way to make it strong and sturdy that I have found is
tons of zip ties. You can also use grids under the second level to keep it up. I did this once when I had storage shelves above the cage, but with the girds there, it gives them less room to run around, so since I don't really use them, they are gone now. Here is a picture of my cage, so you can see what I mean by the grids holding up the second level.


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