Shall do. I'm getting it off a guy who imports loads of it from America, so hopefully it'll all pan out and I'll pass on the details. But, I'm in no hurry to get it sorted just yet, so you might have to wait a while if that's ok?
The base is probably one of the trickiest things to build properly. I'm going to go with an idea similar to this:
http://www.captivebredreptileforums.co.uk/showthread.php?t=6932
By making the floor in a similar way to how he made the walls, I should be able to make contours that drain the water away, and yet still give me a solid base to put plants onto. I asked the guy and it's completely water proof. He just hoses it down to clean it so it's ideal for a bottom. If you keep it smooth too, it'll be easy to wipe clean!
Any sort of stain will do, as long as you give it plenty of time to air so all the fumes dissipate. Decking stains are probably the best option as they're very hard wearing so will stand up well to the conditions in a chameleons enclosure.
Maybe make the males side 3ft wide and 2 ft deep, then you'll be looking great. The female will do fine in 2ft x 2ft x 6ft, but a little extra for a male is generally a good idea.
Yeah, I'll try and draw up a list of all the threads I've looked at on different forums so you can have a good look at all of them. There are a lot so be warned!
This thread has just started up so hopefully it'll get some good results soon:
https://www.chameleonforums.com/diy-cages-24534/
My plan is on there, but it needs finesseing just a little before it's ready to build!