I'm about to dive in and build my first paipo!

1. I was planning on using T800 epoxy for joining, but I now realize that starting with finished-thickness 1/2" lumber leaves little room for error in terms of sanding/grinding down adhesive that squeezes up through the cracks. Any thoughts? Would a water-based (Tightbond-type) glue be easier to work with?
2. Since I'm about to head out to Woodcrafts to do some shopping, what tools do you use for shaping the rails, and in what order? I have an orbital sander. I imagine some files and rasps are in my future.
I'll continue to poke around the old Rodntube site for archived expertise as well. Thanks in advance!