1) smore kit contains one pack of grahams, some marshmallows, sticks and chocolate, I never have bought one since we bring our own, IIRc they are about $5 maybe a little more. My guess would be enough supplied stuff to make smores for 4 (one round only)
2) lots of people roast hot dogs, you will fit right in.
3) I think the sticks are about 75 cents and sold individually or with smores kit
(again, I bring my own so I am not totally sure on price)
4) depending on the time of year and the crowd level at WDW in general arriving 15 min early will usually get you a decent seat. If its during a holiday or busy weekend you should arrive a little earlier. Keep in mind that I have NEVER had to stand through the movie, there is always room in the bleachers.
The closest I saw it to totally full was Christmas eve a few years ago.
Transportation from the lodge could be as little as 10 minutes or as long as 30 depending on if a bus has just left. Once at I think you may have to switch busses to an internal (orange IIRC) or walk from the settlement to the meadows recreation area and take the little bridge over the canal to the campfire program, maybe a 10 minute walk at average pace from the settlement.
5)The only time I ever notice any bugs is during the summer and I wear long pants and bug lotion and dont have any problems, Dec Jan and Feb are never any bugs.
6) depends on luck and crowds at the time you are there, the last few times we have eaten at TE has been as walkups. Ressies would be a must during a holiday.
8) Unless they changed it and didnt tell anyone the show starts at 8 during the summer until the time change (try googling it and see when it is) after that its at 7
let me know if that helps