Q4) Just how does a crusader recover maneuvers anyhow? (This may have been answered, but it's given my arenas countless headaches)
The easiest way to illustrate this is with an example.
1) Take any 5 maneuver cards, put them in a pile and shuffle them.
2) At the start of any encounter, deal yourself 2 cards (3 if you have the extra maneuver feat), face up. These represent the maneuvers you have available to you, which you are free to use at any time.
3) At the end of your round, deal yourself another maneuver card face up.
4) When you would deal yourself your next maneuver card, but are unable to do so (because you have no cards remaining in the deck), collect all your maneuvers together (both expended and unexpended), shuffle them and deal yourself 2 new cards (or 3 with the extra maneuver granted feat).
5) Rinse and repeat as necessary.
Is that clear enough?
Q2) Can swift actions be used as move actions in the same way that immediate ones can be used as swift, and move as standard, and full-round as a standard and a move action?
Unlike 4e, 3e has no known mechanic for converting move actions to extra swift actions, nor would I recommend it, considering how it allows spellcasters to cast up to 3 spells/round, or martial adepts to use 2 boosts in addition to a standard action strike in the same round.