Well the only questions I can answer really are 3 and 4:
The 'official' version of MiniB3D does not support normal mapping at this time, and won't for the forseeable future.
Check out the toolbox for animating tools, I believe CharacterFX is a popular one.
Does/Will Minib3d (or max3d) support normal mapping? I understand that Max3D will be shader driven. I will asume it will support normal map per-pixel lighting. the .b3d format supports 2 UV sets. should there be a 3rd for Normal maps?
The 'official' version of MiniB3D does not support normal mapping at this time, and won't for the forseeable future.
4. What is the best way to animate rigid bodies. I used .3ds files because they did a great job with transformations and rotations, with .b3d, everything needs a bone.
Check out the toolbox for animating tools, I believe CharacterFX is a popular one.