Hey Mike I am still not sure about 119.84 being special compared to say 120 BPM. We are talking a difference of 0.16 BPM! And that is in a tempo of 120 so we are talking now a change of only 0.1% change in tempo. Do you really think you are going to feel that.
Creating audio parts early is OK if the DAW in use is OK at time stretching. I use Studio One for example and all you have to do there is alter the project tempo and all the audio files get time stretched perfectly to the new tempo. But even as good as it is I would not be wanting it to be making major changes in tempo though. Small perhaps.
I use quite a lot of external midi (hardware) as well as virtual so I think it is possible to avoid audio all together for quite a time before settling on the tempo. I work like that a bit if I am involving synths a lot. But if it's a band I think it is better to get down to sorting out the tempo pretty early.
Anything related to 12 is good isn't it!
Tempos of 120, 132, 108, 96, 84, 72 etc are all good! I am not sure about that really. I think you have to just feel it where it should be and be prepared to fine tune if necessary.
Yes you do sometimes have to alter the tempo in a second DAW to keep things right. You start by setting it to 120 BPM as you would expect and at the start the second DAW metronome is perfectly in time but not right at the end. In this case the metronome will be early right near the end of the piece compared to the music in the second DAW. Early means the second DAW is playing fast and you might have to shift the tempo down very slight amounts eg 119.84 and then everything will line up again nicely. Not sure but I think in Logic you can set the tempo to 4 decimal places. This is also when audio is involved not midi only for obvious reasons.
Another place where weird tempos show up is in film scoring. Sometimes you have to alter tempos very small amounts to meet up with hit points perfectly as well.