mcolex.
Your looking at some major networking issues if you do this slowly.
For an AD domain, you need DNS to be administered by that domain controller. Also, your machines need to be within the same subent and IP space. So, I would recommend setting up DNS as well as DHCP. Then, I would disable your router's ability to provide DHCP to your LAN.
I assume you want to eventually graduate to a flat domain with your AD domain controller as the head of it. This means all on one IP space with a DC, samba server ect..., correct me if I am wrong.
We can do all 40 machines and your Samba server within the hour if you wish.