Yes. Mesh-compatible objects are exported to their own files unless you group them together.

Sounds like a Blender problem. Try asking for help on the official website.

They must have increased the limit for SFM. I'll look into it. If you can work out the new maximum that would be great...

They are created as Actions. That's all. There is no way to link aninmations to objects, much to Blender's detriment.

No idea, it's probably something done by the FBX exporter. Or perhaps you already imported the animations at a different time and Unreal is linking them up automatically?

When importing the weapon you need to uncheck the "append to existing model" option. Then go into pose mode and add a Copy Transforms constraint to the weapon bone, targetting the character bone with the same name.

What are you importing, and in which exact order? It would help if you uploaded your blend file.

You'd do better asking this in the Blade Symphony forums.

I can export a cell fractured object without any issues now, without any bones anywhere. Can you upload your blend[www.pasteall.org] for me to take a look at please?

Download the beta again and things should work.

If new items appear after an export, you are probably running Blender in debug mode 2 or higher. Reduce the value with Ctrl+Alt+D.