I fell on this in a magazine. Its a freeware with tons of function and just what people who don't have photoshop or paintshop and want to mod rebellion need.
The crashing of the game upon entery of the tactical screen is a common anought problem. I can't really remember what causes it though. Did you put some new models in the game?
How about each admiral knows a certain amount of moves. He can receive more if you send him on training missions. He can also give your ships a moral bonus.
One major question. How are we going to set space battles? I am not very keen on using a 2d plane like EaW but i also think that the original rebellion interface isn't really adapted to create real strategies.
YOu mean when they evacuate Reech? I think you should do it during the battle of Reech. You would be a group of Marines who are trying to reach the Pillar of autumn.
Halo was succesfull mainly because it is a very good games by console standards. The Sequel was good but the ending was appawling. The first one was good but i found the gameplay a little light (not many weapons or environements)
I don't think you can reduce the cost to zero. Basically to make a TC you use RebEd and then depending on what you changed you zip a DLL file and upload it on the site.