I think SM is a pretty cool guy, eh builds unicycle-bots and doesn't afraid of anything
Does that not defeat the point of using a texture with a higher resolution?
You're going to have to manually apply the decals in your image editor of choice if you want to apply them. It's easier to do in an image editor because decals don't come out as a blurry mess most of the time like they do in RA2.As for edge lines, you can paint your bot red and apply edge lines before you export it, and then just export the bot skin as-is and edit that.
When you export the template, the green edges aren't the place where the edge lines are? I would use a program that let you make different layers, so you scale the template, make it transparent and put edge decals on where the green lines are.