With regards to the 60mm flat port, should I opt for the port with manual zoom gear? Would this prevent me from using the AF setting if I wanted to?
I assume you mean focus gear. The 60mm doesn't zoom. No, this would not prevent you from using AF. It is my opinion that it is unnecessary to get manual focus version for the 60mm lens. AF has always worked fine with this lens.
Considering the 12-24, is there a significant difference between the 6" dome port and the 8" dome port, and is it worth spending the extra?
I haven't seen comparative results for this camera and this lens using both ports. You will likely see no difference in performance in the 16-24mm range, but will likely see far less edge distortion in the 12-16mm range. I cannot comment on the worth of the extra purchase. Some people will value any improvement, while others have been quite content with the standard Ikelite port.
Now for the strobe options. Which is preferable considering the two lenses I will be using, two DS125's with one connected iTTL and the second with a slave sensor or both strobes connected via a dual sync cable?
Always use a sych cord when you can. (I know some people will note some exceptions to this "guideline"). Get a dual cord. As suggested, get a single cord backup. This is how I traveled for years.
inally when travelling with all this gear, what size Pelican or other travel case would be needed to store housing, strobes, arms, chargers, dome ports, etc?
The camera itself and lenses will be travelling with me in a Lowepro rucksack.
There are lots of threads on this topic. I'd point you to them, but that would take effort on my part and I am extremely lazy. My strategy is different from most others. I've abandoned all my hard cases, e.g. Pelicans. They are heavy, bulky and with foam in them, don't really hold that much. My single traveler stategy (without using the purse option) on airlines that allow one carry-on and one personal item would be a roller carry-on suit case that does not exceed the 45" limit imposed by most carriers. Skip the ones with lots of padding and external pockets. I wrap housing, strobes, ports, etc. and pack it full, assuming no weight restrictions. I would then recommend the Computrekker as my laptop bag. There is a monstrous Computrekker Plus version that is much bigger. The basic Computrekker is a mini-trekker with laptop compartment added. It is not huge and fits nicely under the seat in front of you.
Options change depending on airline, destination and equipment taken. I've got all sorts of camera gear. I pick and choose what I take on each trip since I can't take it all. Then I pick the bags that work the best. My strategy: 1) Maximize internal cubic space, 2) Minimize likelihood of forced checking or separation from your carry-ons 3) If you can't carry it, don't take it and 4) If you must violate #3, pack in checked bags somthing that won't stop you from shooting, e.g. don't check sync cords, if you lose a checked bag or they get stolen, you can't use strobes, if you check a dome port and lose it, you still have the flat port with you.
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