I'm uncertain exactly what format we'll take. I do like the concept of keeping it simple with two characters, one protagonist for the player and an NPC companion. There are some thoughts to try and just have one of each instead of an NPC roster, provided the two are still reasonably balanced (the combo being thrown about is an Occultist and Gunslinger, the occultist being just extraordinarily flexible in its spells and the Gunslinger being a good assist for combat and ranged attacking). With a roster, I'm worried I will be overly generous in allowing more than one NPC to join on quests if requested or in character. But obviously a certain amount of meta comes towards fixing that.
I'm somewhat making a "Heroic" template for the Protagonist so that they'll be extra buffered and capable. 30-Pathfinder Point Buy and a bonus to HP equal to Con score. Though i intend the NPCs to be of regular squishiness so retreat actions will depend upon the Hero calling things if their friends are in danger.
If I didn't think it might overwhelm and over complicate characters, I might look into gestalt rules, but Heather is still fairly new in the mechanics of D&D and I don't want to overwhelm and make the grindy bits too heavy and the game unfun for her.
But we'll have to see when I'm actually able to run and record such a venture. You seem to be doing some not insignificant prep, changes, and foreshadowing in kingmaker, and I'm trying to fully prepare whatever we choose as an AP to really tie all six books into something special though sometimes I can take too much time there. But, the lovely thing about a good prep is that it leaves notes to run for another group later .
It's a shame the Jade Regent sessions weren't recorded, I would be tickled Pink to hear how a game inspired by my running turned out. i can't think of all that I did differently to be honest.
Regarding the Hero points, do you have any cap for unused points? 4 per level is quite generous.