Well, I haven't solved the mystery yet, but I can already admit to one conceptual mistake: I forgot to read the source code (and relied, instead, on documentation and existing threads in the Zen Cart forums). 
Also, so that I can save other beginners from the same syntax mistake, the correct syntax for accessing the $orders->field[] array elements is $orders->fields['customers_name'], not $orders->fields[customers_name] (long live single quotes...)
Fixing this syntax mistake didn't help, of course, because IMHO my problem lies within the scope/lifetime of the objects I am trying to "snatch".
In the meanwhile, I am providing here a snapshot of the my partially working solution, along with what actually gets written to the file:
includes\auto_loaders\config.writeCustInfo.php:
PHP Code:
<?php
$autoLoadConfig[90][] = array('autoType'=>'class',
'loadFile'=>'observers/class.writeCustInfo.php');
$autoLoadConfig[90][] = array('autoType'=>'classInstantiate',
'className'=>'writeCustInfo',
'objectName'=>'writeCustInfo');
?>
includes\classes\observers\class.writeCustInfo.php:
PHP Code:
<?php
/**
* Observer class to write customer info to a temp file.
*/
class writeCustInfo extends base {
/** constructor method !
*
* Attach observer class to the global $zco_notifier and watches for a single notifier event.
*/
function writeCustInfo() {
global $zco_notifier;
$zco_notifier->attach($this, array('NOTIFY_CHECKOUT_PROCESS_AFTER_SEND_ORDER_EMAIL'));
}
/** Actual Method that writes customer info to file
*
* Called by observed class when any of the notifiable events occur
*
* @param object $class
* @param string $eventID
*/
function update(&$class, $eventID) {
$myFile = "testFile.txt";
$fh = fopen($myFile, 'a') or die("can't open file");
/**
* Write the following fields to a file
*/
$stringData = "This is the first line of ";
$stringData = $stringData . $myFile;
fwrite($fh, $stringData);
fwrite($fh, "\r\n");
$customerInfo = "Customer Information: \r\n";
$customerInfo = $customerInfo . $myFile;
$customerInfo = $customerInfo . $order->fields['customers_name'];
$customerInfo = $customerInfo . $order->fields['customers_company'];
$customerInfo = $customerInfo . $order->fields['customers_street_address'];
fwrite($fh, $customerInfo);
fwrite($fh, "\r\n");
fclose($fh);
}
}
?>
The output, in testFile.txt:
This is the first line of testFile.txt
Customer Information:
testFile.txt
I will post here the complete solution, once I have it. But if you notice any gross mistake in my code that could explain the mystery, that would help me post the solution faster. 
Thanks,
Daniel
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