Split the difference. Do both. Leave HQ in Colorado Springs, build new facility in Hunstville to liaison with those resources and capabilities.

Talk to a lawyer - their may be less expensive ways of doing it if you will only have a small amount of revenue.

But also speak to you accountant - I was given very good advice as a courtesy. Most of it was to keep business and personal funds completely separate.

You should consult with a lawyer and an accountant here in Massachusetts. LLC offers some liability protection over a sole proprietor arrangement. May be some specific requirements for an LLC depending on what services you are offering. There are tax and ownership issues that you also need to understand.

A simple LLC should cost you $1k to set up - $500 for legal fees and $500 for filing with the state.

I would recommend looking at the energy/sustainability space. Lots of work, and while your engineering skills may be a bit rusty, I suspect that you can build a a good story to map your skills as a teacher into a project management role which is always in demand. I would suggest talking to a professional coach to help build and practice that story.

You need to get your foot checked out. Your situation is the definition of an emergency - a medical condition requiring immediate attention. You should notify your PCP with 24 hours of the visit and followup with them

Many Urgent Care centers will bill as if they were an ER, especially to out of network patients. I would also suggest going to a Urgent Care center that is affiliated with a hospital if possible - they tend to be better staff ed and equipped than as stand alone center