square footage per bird if they have access to a large run

Well, I'm going to go with the 4x8, but I have also been thinking about making it open on the one side anyway because of the heat in the summer. At the same time though, I think I like the idea of them being in the coop at night just in case something gets in. The top of the run will be covered with fencing but not hardware cloth, it'll be the kind that has larger holes in it..not sure if anything could get through there. Our yard is fenced in so I am not concerned that dogs could get into them, and I haven't ever seen anything like a raccoon even around here, but I don't know what will turn up once there is chickens there! Maybe the wall facing into the run could be mainly hardware cloth though. Which, would add to the cost but it'd also make it breezier, which could be good during those humid summer days.
 
I've used 2x4 welded wire on my runs (including run ceiling) and never had an issue with critters getting in. I would definitely go with hwcloth if you do a wall panel for your housing though, as anything could reach through those 2x4 openings. If weasels are common in your area (they're not in mine), they will dance right through the 2x4 stuff, but it's worked well against raccoons for the past three years for me. All of my runs have smaller wire around the bottom 24 inches, to prevent reach-ins. Some just use chicken wire (over the welded wire) for this, while others add hwcloth.
 
I've used 2x4 welded wire on my runs (including run ceiling) and never had an issue with critters getting in. I would definitely go with hwcloth if you do a wall panel for your housing though, as anything could reach through those 2x4 openings. If weasels are common in your area (they're not in mine), they will dance right through the 2x4 stuff, but it's worked well against raccoons for the past three years for me. All of my runs have smaller wire around the bottom 24 inches, to prevent reach-ins. Some just use chicken wire (over the welded wire) for this, while others add hwcloth.
I don't think we have weasels, but I should look into it. I've never actually seen anything around here other than small garden snakes in our yard waste pile, squirrels, bluebirds, sparrows, doves and a woodpecker. Oh and bugs.

That's exactly what I am planning, bottom 24 inches as hardware cloth or poultry wire and then the top the welded wire. Any wall of the actual coop will be done in hardware cloth for sure, I want to be sure that they're completely safe when they're in there!
 

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