Question 11: Yes, it's totally hard-coded. However, it can be worked around. All you have to do is open up the përs resource for each person in question. Take a look at what outfits and shield strength they have, then make a copy of their ship (so in the case of TomWoozle, the Manticore), give that ship all the outfits and shield/armor upgrades that the përs has, then go back into the përs, set their shield strength to 100%, delete the custom outfits, and make their ship type the copy you just made. It sounds complicated, but what you're doing is just making a ship that's exactly like the përs, so that the përs doesn't actually change anything. That way, when you capture them, they will stay the same.
Question 10: I'm pretty sure I've got a solution that requires minimal effort. Give the spöb that's supposed to ignore the require bits/tech levels/mission bits a unique tech level (like 500). Then, make a copy of the outfit you want to appear there. Keep most everything the same, like cost, weight, max number, etc, but change the availability, tech level, and most importantly, make the outfit not do anything (set all the ModTypes to "None"). You'll also want the picture and description to be the same as the original weapon you copied. Then, give the new outfit gXXX where XXX is the original outfit, and give it dXXX on sell.
Now, of course, you're going to have to make the relationship work both ways (so that you can't max out the outfit normally and then max it out again using the special availability place). So open up the original outfit, and make it grant XXY (the new outfit) on buy and delete XXY on sell.
Now, we're left with one problem: buying either outfit is going to take up twice the space (and/or gun/turret slots) that they would normally. To get around that, you're going to have to make a second, one that gives back a number of tons equal to the outfit's weight, and gives back one turret or gun slot if applicable. This will be XXZ. Set both the original and new outfit to grant this outfit on buy and delete it on sell. So if it's a Medium Blaster you're talking about, you'd give outfit XXZ -8 tons and grant one extra gun slot. Hope that makes sense.
There's an easier way to go about this, but it involves the sometimes-finicky business of invisible missions (since they either take up a mission slot on the character or interfere (and are interfered with) by other missions available from the same planet's spaceport). If you wanted to do that, you'd just make a mission available from the spaceport of whatever planet you wanted the outfit to be available at and give it the appropriate tech level. Then, add to the end of the outfit in question's availability: " | bXXXX". Have XXXX set when you land there via invisible mission, and make a crön that runs if bXXX is set that will clear it. Also, if you don't want other outfit of the same tech level to be available from that spöb when/if they become available normally, you'll have to go into each of them and add to their availability " & !bXXXX" so that they don't show up at that spöb.
This has a slight possibility for interference with and from other missions, but if you're not expecting any missions to pop up where you have the outfit, it shouldn't be a problem. This way is much easier and less resource-intensive, but if you want a sure-fire way of going about it, use the first suggestion.