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Bitspudlo just posted pics of their new servo arm kit and it looks very nice. They're very reasonable price wise as well.

I second Simple Green or Fairy Power over brake fluid. I've used SG and brake fluid myself and found they do about the same job, but the SG is non-toxic and much safer. Even still, protect your hands from over-exposure with nitrile gloves.

Gitsplitta has an extensive RTB01 collection with loads of great conversions. Check out his blog for some inspriation and advice.

Check the News and Rumors Forum for Bitspudlo's servo arm. About 1/4 down that page. Still in the "building stock" phase so it might not be on the site yet.

Very easy as long as you take care with it, building in layers, bulking as you go, and letting it cure completely before moving to the next stage.

There's two tutorials I'd recommend here on dakka: frock coats and tricorn hats for pirate orks (just trust me - it makes more sense after you read it) and Whatwhat's Greenstuff Tips and Tricks.

They'll give you the basics to work with to keep your cloaks looking like they belong on your model. I used them both when making my counts-as Tellion conversion.