I didn't come up with those, but borrowed them from a comment on discord by someone who seemed trustworthy, and I didn't question it much. The Rebel lord was too complex that I bothered to do the math, for the mind-locked wyrd I think it's as easy as you suggest, take the Outcast leader cost, get free wyrd power access and add cost for mesh armour (it's a rather naked character). This won't be exactly correct, but accurate enough?
My impressions for your other questions are (not 100% sure, please correct me if I'm wrong):
- No. But you have access to the same equipment as those fighters as common (if they are available from the trading post), so you could re-buy most of it and give to standard Outcast Champ/Ganger.
- The special characters are typically overcosted, so cost should not be an issue.
- Yes, that's incomplete. And it's way too much details to solve completely in one single book. I think you gonna have to either accept that you lose the equipment, stash it and replace it with what you really want (be a proper outlaw and break the rules!) or simply set a strict limitation to take the character as is (don't remove or replace anything). In general, I think it's more about using anything you want rather than having the correct costs for everything. Err on the side of caution! And yes, you are correct the same problem with built-in armour (and other equipment) is the same problem here. The dilemma is, do you want this imperfect option to use anything you want, or a perfect system without this option.
I'm gonna list up some of these points as errors, because they are, but for once I think there are more important things in the game to handle.