What do I have to do to make a TC mod completely stand-alone.
I know that I need a number of things like sounds, interface and various other bits of data, but TCs like TBP or BTRL ussualy have a lot of stuff in their folders besides FS2_Open builds, FRED and Launcher.
Basically you need to replace all art assets that are either

original or based on the

original (MediaVPs/FSPort). Probably the best way to go about it would be extract all of the original VPs (that would be Root_fs2, the tango trio, sparky, stu, warble and smarty) and look at them and see what they are and replace them one at a time with the the TC assets.
I would do this by creating a new folder, put a fs2 binary, a fred2 binary in it and a launcher, extract all of the original fs2 content
1 into a mod folder (called
tobereplaced), setup another mod folder called
dragontc and start replacing everything one by one.
This means that your root folder is empty so that you can test at anytime to see if your TC is able to actually run standalone. This would be done with some tricks of mod.ini. For
tobereplaced make the mod.ini to have
dragontc as the secondarymod (this way you can check your work without the engine complaining and/or crashing because some art is missing). When you want to test the completeness of your TC, set the mod to
dragontc. When you are ready to release you can move the data in
dragontc back to the root folder (don't forget to put them into a couple of .vps though) and now you have a standalone TC.
I'd like to know what do I need to do to create a TC that can be installed on computer that never had FS on it and things like how to create the (preferably off-line) installer.
As far as off-line installers go, wxLauncher should be ready to be used as an installer by the time that you are ready to release. As an added bonus the wxLauncher installer will likely have been field tested at that point by Diaspora and possibly other TC's
2.
It could help all TC mods which do not depend on retail data, widening the range of people to who they're available.
Yes, and you will likely run into many bugs or parts of the interface that you cannot change, because the binaries store a large part of this information within themselves and is not actually user replaceable. TBP, for example, has found a great number of bugs related to this, and I am sure they are not done yet.
1) Though strictly speaking you don't actually have to extract all of the content, you could just leave them all in the vps. But extracting them is also useful as a reference so you know what is actually in the .vps that you need to replace.
2) I only mention Diaspora as they are the only ones to have mentioned any interest in doing this this with wxLauncher at this time.