-Lights, up to a 75 gallon (personal experiments) can be placed in the same pot resting just above the terrarium long term. Above that, and after a longer period of time the heat does indeed finally get to the mesh. If you moved it around often enoguh, I suppose there would be less degredation of the mesh.
-Flexariums block plenty of light and UV. I would choose to put a ficture that holds two or more fluorescents over them. Keepers do notice a change in colour between chameleons housed in Dark Flexariums or other cages. Adding aditional lighting will aid in doing the same. (Also note, a 10.0 bulb is not the same as two 5.0 bulbs).
-Walls inside flexariums are easily made. Buy some Corruplast (Corrugated plastic) from a home or hardware store, or plastic/PVC supplier. If you want three walls covered in your cage, take measurements for the heigt of the cage (from the bottom of the black frame, tot he top of the black frame,) and then measure the widths of each wall it will be on. Add those measurements up, plus 2 inches. (Plus one inch if you are only covering two walls- as this accounts for bending the plastic.) Cute the board into one sheet using the two measurements, witht he folds in the cardboard going vertically. Take your flexarium mesh of its frame. Tape on end of the board to the frame on one side, and bed it around, then tape it on the other side. Slip the Flexarium cover back on, and then remove the tape (important!). Voila, some new solid white walls. White will help brighten the cage also as explained above.
-Zipper troubles. Take some vaseline or petrolium jully and put some into the zipper, and open and close it a few times to spread it out. Repeat every month if needed. No more zipper woes.
Hope this will help someone.