An event structure does not use any resources as it waits for an event so I don't understand your comment at all.
There is a shipping example called Toolbar using Splitter Bars. Yes, you have to create your own Booleans unless you place an ActiveX toolbar at the top of the panel.
In general, you should be using the system palette to reproduce a ms dialog. Post what you have written so that you can show what you don't like about the appearance.
And, what is the exact difficulty you are having in transfering back to the main VI? The most basic method is to use the subVIs connector pane. If you have a lot of variables, bundle them together.