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You have to be the King yourself, so you have to own kings landing for a small period before it declares you the current king.

Then you can recruit them when you rescue them

They do not repawn.

The sellsword companies are as follows (taken from the wiki)

Stormcrows

The Stormcrows are 502 unit large troops entirely comprised of Veteran Freeriders and 2 unique units. Their leader is Prendahl na Ghezn.
They can be found near Myr and costs 100,000 to hire.

Moonbrothers

The Moonbrothers are approximately 200 unit large comprised of hill tribesmen faction units. They are of the minor faction Hill Tribes.
They can be found near Gates of the Moon and often roaming towards Moat Cailin

Wild Hares

They can be found in the North

Second Sons

The Second Sons are 503 unit large troops entirely comprised of Veteran Freeriders and 3 unique units. Their leader is Mero.
They can be found near Volantis and costs 120,000 to recruit.

Unsullied
The unsullied is a unique company that's available for hire but do not roam the map like the others or aligned to any faction. They are an elite spearmen which can be upgraded to Veteran Unsullied.
The unsullied and veteran unsullied have zero cost upkeep once your purchase them. Upgrading still costs a significant sum.
A man in the inn of Qohor sells Unsullied for 75,000 for 50 units at a time. A week of game time must be passed before you have a chance to purchase them again.

1. It was possible, but you need to be declared king then rescue them as prisoners from another castle/lord and they "might" join you.. dont think its 100%

2. Doesn't happen until late, day 800+ or something (cant quite remember as im an addict and days melt together), you can defeat them with troops that have fire arrows/obsidian/valyrian steel.. trust me its not meant to be easy.

3. http://aworldoficeandfire.co.uk/wiki/index.php?title=Valyrian_Weapons

4. No, he only has the 1 line.

5. Only if you place very cheap guards and still not great profits...

6. Legit is alot more hassle but alot more rewarding and fun, dont be tempted to give yourself gold etc... you'll feel better knowing you earnt everything you and your companions wear

There are still 2 more day affected events to come, I wont spoil it though.

One will come soon-ish and another much later.

Is that intentional?

As seems a bit weird that you can take over the westerlands and all of a sudden the villagers are all wildings

Yes all of this has been done, what I meant is that it doesn't seem to actually change anything.

Asking the question for clarification, if you pick wildling as your starting character past are you locked into only having your villages produce wildlings?

Whenever I've decided to start a wilding (mainly for the giant companions) my villages only produce wildling troops no matter what I change my culture to.

Is this a feature or a bug?

Thanks

No he does not, the red wedding quest line is only to either keep robb as king or make bolton the warden of the north.

You can start your own faction that doesn't involve attacking another faction by finding a quest where you rebuild a castle.

You can make your companions into vassals, you get an option in their dialogue that says "can you hold a fief for me?", they will always say yes and they become a vassal of your faction.

As far as im aware the settlement never really becomes like a castle if thats the way you mean, I could be wrong. You can store troops/items/hide in it etc but I've never had a situation where they have ever attacked it.

You cannot rework an already complete valyrian steel weapon, most of them are held by lords but you can get 3 (swords) from doing quest line or purchasing

Bribe to make peace with them

The one I spotted the most often that has wacky spawns was Salt Pans

Yeah you can, I accepted one and checked him with the spy master and he wasnt honourable... but now i dont want to cast him out... so im just not giving him any fiefs/castles and waiting for him to get sick of it and leave.

Im trying to do a play through with Honorable lords only

Sorry to bring this subject back up.

Once the lord is waiting in your capital then how do you tell? (As they don't appear on any selectable faction)

Or is it simply a case of if they have been thrown out for treason they are only going to be dishonourable lords anyway?

But thats cheating