Thanks, =X=! Glad to hear it's going in the right direction!
I assume when you say the font size might be too small, you are referring to the first (10pt font size) document.
Here's is the same document with 11pt fonts, and a smaller margin. (I should note that the 12pt and this 11pt PDF's did not have their bookmarks and related metadata fully fixed up yet.)
Is it better? How do you find the margins? (They are now the thinnest they can be made due to the idiosyncrasies of the text's typesetting.) Is the ruled header helpful and non-disruptive? Are the page numbers helpful, or do some readers have automatic page numbering that it may conflict with?