So can someone make a guide or something that puts exactly which steps are more or less necessary for minors to expand?
Not much time, so here's a quick and dirty guide.
1) Edit raceconfig.xml
2) Start game, but don't play
3) Immediately Quick Save
4) Load Quick Save
5) Play.
In detail:
1) Edit raceconfig
Find it at: C:\Program Files\Stardock\TotalGaming\GalCiv2\Twilight\Data\English\raceconfig.xml, right click and select [Edit]. That will open it in Notepad. Scroll down and notice the pattern of each civ being listed with its abilities. Scroll down until you find the minor civs. Notice how each has the entry <AIPersonality>5</AIPersonality>. AIP 5 is pretty much stupid mode. All the majors use a different personality.
The basic idea is the change the <AIPersonality> from 5 to 11 and add a few key lines from the major profiles, specifically the:
<AIAbilities>50</AIAbilities>
<Aggression>50</Aggression>
<FinancialResources>100</FinancialResources>
<CPUUsage>100</CPUUsage>
So, change the AIP from 5 to 11 then cut-n-paste the lines above right under the AIP. Do this with all the minors and you're set.
2) Start game, but don't play.
3) Immediately Quick Save
4) Load Quick Save. This step is vital. There is apparently something in the game initiation that sets the minors up in stupid mode. By saving and reloading you force the game to use the abilities that you've put into the raceconfig.
5) Play. Have fun. You've now got yourself some colonizing minors.
You could do any other modifications you wanted, but those are the basics. You can set their political parties, give them super abilites if you want, or change their race abilities to tailor each race. I made some races good, evil, and neutral, set them to different political parties, and made a couple more aggressive just to see how they'd act. I changed their ECONOMICS from 100 to 0 and took away all the bonuses the Akilians get for whatever reason. I haven't had a change to playtest it yet, but I figured that would let them expand while keeping them minor.
Good luck, and let us know how it works out for you.