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To be honest Terry, it's really a matter of preference. If I have a lot of cake to do, I prefer to bake and freeze ahead. That way I know I have them done and there will be no last minute disasters with sinking, breaking, overbaking etc.(but then, I am a worrier!). Also, I get too to tired trying to do it all in a couple of days. I prefer to pace myself.
If you do it all in one go then yes, if you crumb coat it will easily stay good until the next day. Better that way, then your coat can form a crust for your fondant to lay smoothly on. If you want to you can also cover with fondant, that will certainly keep your moisture in, but shouldn't be necessary.
If I were doing it all in one go, I think this would be my process -
Day 1. - Bake, cool, fill, wrap in cling film and put in the fridge to firm up.
Day 2. - Carve, chill, crumb coat .
Day 3. - Cover in fondant. You can then stack and decorate or leave it till the next day (covered, but not in the fridge).
This is just my personal preference and I'm sure others would do things differently. But I am not a professional, so need time to do things!
These might help you: www.thebakerspantryco.com, http://www.cakeboss.com/PricingGuideline.aspx
Terry, the only way I can think of is to add up the weight of all your ingredients for the cakes, buttercream and fondant.
As for a board, a standard cake drum (12mm) should be strong enough to hold it. That's what I always use for larger cakes. Sizewise, you probably wouldn't get one that is 12 x 15 as they tend to be of even measurements, so 12 x 16 would be the one to go for. This is what I would use from my UK supplier -
http://www.craftcompany.co.uk/cake-boards/cake-boards/12mm-oblong-s...
With the box, (this is again only what I know I can get from a UK supplier) - you can get stacked cake boxes, but they are quite pricey. As an alternative, get a normal box with side extensions to make it high enough to take your cake with a lid. Like these -
http://www.craftcompany.co.uk/cake-boards/cake-boxes/extension-corn...
You may have to trawl the internet a bit to find them where you are and order them online.
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