Based on what i know (so far);
1/Yep (see other replies)
2/"          "         "
3/Yes (see FSMM2), you can also add the thruster flames using a seperate sub-object (thrusterxx) tiled with a map named thruster01 (i.e), which kinda 'links' to the thruster01.ani.  I've yet to try this myself, though, but I think there was a thread on it a while ago.
4/ ditto (NB:  FSMM2 sometims crashes when adding fuel chunks - I'd do it first)
5/Yep (glued as child).  Depending on the type of turret, you have to glue a local light as sibling to either the base (1 part Turret), or the barrel (2 part) to create it on a seperate level on the heirarchy.  there's a tutorial on this somewhere, again check the FS2 Modding board for it
6/..see above
6(b)/Not sure - but maybe you could try using Blender ( 
http://www.blender.nl  ) to create the hull object dxf.
NB:  I don't know if you're aware of these things, but ;
-you have to create the shield mesh yourself (either importing from another pof or using segletuchs autogen)
- you'll probably need to do all the LODs, especially for a complex model (not sure on exactly how - I've asked in another thread). 
Hope this is useful  
