As in my previous post, I should quantify this by saying that I'm new to Bitcoin as of yesterday. I just happen to know a bit about encryption and file systems.
1 - So tell me if I understood this right - you wallet is a physical file on your HDD (wallet.dat) and it contains all the addresses (the long strong of characters/digits) created with the bitcoin program, correct?
Correct, given that the program was using the same wallet file each time a key/address is created.
2 - If the above is true then technically you could have one wallet with 5 addresses and if 4 different people send me coins to each address then all these coins together would be contained within the one wallet?
This I'm not entirely sure about, but my impression so far is that the client connects to the Bitcoin network and makes note of any Bitcoins currently owned by the addresses in its wallet. The sum is displayed as your current balance.
3 - Hypothetical scenario - I secure my savings wallet containing 100 coins on a flash drive, by cut and paste. Then I restart the program so a new wallet is created - I record its only address and then delete the wallet. Then I copy the savings wallet from the flash drive back to the AppData\Roaming\Bitcoin directory and open the program so it is recognized. Finally I transfer all 100 coins to the address recorded earlier. The outcome would be total lost of all the coins, correct?
If you delete the only copy of a public/private key pair (the public one being your "address"), then there is no way to claim ownership of any coins belonging to those addresses. This is why having a backup copy is a good idea, as long as both it and the original are reasonably secured.
4 - I would guess the Bitcoin program the the wallet should be kept on a separate machine and not on the Mining rig?
It doesn't really matter as long as the wallet is kept secure. If the mining rig is a well-secured linux box, that might be the best place to keep it.
5 - If you secure you wallet on a flash drive and then someone sends you coins on an address that is contained within that wallet when do the coins actually appear in your wallet? I mean that wallet is "offline", so how will the transaction work out?
The transactions are made and stored on the Bitcoin network. No coins are actually stored in your wallet. When you connect to the Bitcoin network with a wallet (or, more specifically, a given public/private key pair), then Bitcoins owned by your public key(s) are displayed as your balance.
6 - I read an article somewhere that after 50 coins accumulated in your wallet you need to back it up, because you might lose the coins. Is that just pure gibberish?
They were probably just recommending a backup once you have a worthwhile amount. There should be no difference between having 1 Bitcoin or 25,000 - except that the latter is obviously more valuable to you.