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I have never built a helix, but you might want to try 1/8" thick roadbed on it with stiffeners on either side of the track. Similar to this:http://www.bcrdawsonsub.ca/Construction.htmfrom here:http://www.bcrdawsonsub.ca/
3% is probably to steep unless you want more than 2 engines at the diameter you are looking at. The H15/16's are pretty good pullers but if I remember right the AC&Y normally only used 2 loco's per road freight so 3% might tax them a little. Also, unless your lower level is just staging you might want to give yourself a little more height railhead to railhead.
My helix is 21" track radius, 14" climb, 5 turn. I think that's like 2.5 degrees. For me, about 10 cars per loco is all I can count on. Some are better, some not. You are welcome to try mine out with your train if that helps any.Lighting looks good, too.
The lowest level would be Brittain Yard (since it appears you know more about the AC&Y than the average bear ), full height and operational.
I wonder if unitrack could be used without a sub roadbed if supported properly. Same concept as the laser cut birch ply. Seems like big $$$$$ compared to hanger strap and foam though.
I've been interested in the AC&Y for quite awhile now. DT&I also. Please keep up us posted on progress.Yes you could and it would be very reliable and also the track would stay pretty clean. Drawbacks are it's more expensive and you would use a 15" radius instead of 16".