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[Ggobs]

I've done this with a 40x40. It didn't work out too well. A lot of time spent walking around the perimeter.

Actually most of my forts start out as open 10x10's with floors and then enlarge to 20x20 as the fort progresses. 6 levels of 20x20's is usually enough to fit a 200 pop fort. High quality food and/or a mist generator and/or temples/inns are enough to negate any negative feelings.

[Saiko Kila]

I haven't seen a good method to clear the stones quickly.

What I've found to be an effected way of clearing the stones out quickly is to undesignate your miner dwarves on hauling. That is, hauling anything. All they're allowed to do is dig, eat, sleep, and socialize. This keeps them mining out the layers while designated hauler dwarves (Peasants who have no other jobs other then hauling.) move the stones into stock piles.

Though I don't start designating Hauler Dwarves until my fort has >100 dwarves in it, as anything before that is a waste of 'resources.'

Well, it always pains me to enable only hauling of dwarves. I feel that all of them are created for higher purposes So about five jobs per dwarf is minimum in my case.

That said, I do have multiple dwarves hauling at the same time, because I usually make around 10-15 quantum storage stockpiles (with minecarts), which means that the probability a dwarf takes up the role is high. It's just not enough because stones are heavy. Yes, I do have wheelbarrows, but some dwarves prefer not to use them. It's still not as bad a when they carry a minecart with magma from deep below...

[bloop_bleep]

I have an idea. Suppose that you have a mine, where all squares in all layers are mined out, except for a staircase at the very edge that goes down to the bottom of the mine and a staircase leading up from the bottom of the mine that goes to the main part of your fort, which would be supported by nothing except that staircase. Inside your main fort, you would have a hatch exactly one z-level above the staircase to the mine. You would dump a certain fraction of the stones that you mine on the hatch. When a siege arrives, you would wait until most of the goblins are in the staircase leading to your fort, and then open the hatch with a lever. The hundreds of stones will begin to fall down immediately, smashing in the heads of each and every goblin on the staircase, easily obliterating the entire siege.

[h27kim]

How deep a pit are we talking about? 

One idea that I always had, but never actually implemented, was to try to dig all the way down to the caverns, while building "floating" structures in the middle dug out parts that are connected to the sides by constructed floors. 

[h27kim]

I suppose the only issue with my fort idea would be where the hospital goes. Ideally it'd be internal in the stalactite, but then how would the well work? That water has to come from somewhere, and I'd rather avoid having a hole go from the caverns right into my hospital, or some convoluted water redirection system that makes the resulting structure look hideous.

I always build a "hanging" well fed from a surface water source through a set of covered pipes.  I suppose it is an example of the "convoluted water redirection system," but not a hideous in the aftermath, at least, i don't think it is.