Yes, the 12mm AV switches work the same like the 16mm versions, there's no difference.
Now, your Recharge Port questions:
4. I don't own a saber with a kill key setup, but since US doesn't offer special chargers for a kill key setup, I assume the ports are the same. It's just the wiring that is different. Which leads to answer
5. I'm really no expert, but my guess is that nothing would happen.
6. Unfortunately not. I only saw a wiring diagram with the normal Recharge Port setup once, but not with the kill key setup. I don't think that it's requested very often, so getting an answer on this might become a bit difficult...
There was a diagram somewhere showing the wiring of an Emerald/Obsidian setup, maybe I can find that for you.
EDIT: Here it is (even with a Recharge Port in kill key setup according to DarthDaddy) -
http://www.saberforum.com/index.php?topic=20367.msg318821#msg318821If you go through the topic, there is also a post regarding the ground connections which can be simplified.