Well, new update today, I've been poking around at having Kerbals spawning in the main flight scene, and found an issue that needed to be taken care of.
When parts unpack, they reset their rigidbodies in a pretty agressive way. That causes the ragdoll on the Kerbal object to lose references to the root rigidbody, which means the ragdoll joints lose the attached body link, and attach themselves to world space. I don't need to tell you just how much that disrupts normal functioning of the whole system. It's pretty bad.
Fortunately, it was a simple fix. We just needed to reset the ragdoll links that get broken when the part unpacks, and everything worked just fine. Trouble was, the EVA controller didn't know when the part was unpacking, until it was too late. So I set up the vessel and part components to fire off messages when packing and unpacking is being done, to give other attached bits a chance to do stuff.
That worked out pretty well, and I just needed to tweak a few details to get the kerbals packing and unpacking in the game, just like any other vessel. Some cheating later, we had a Kerbal walking on the Mun:
That same jump wouldn't get you more than a foot off the ground on Kerbin. Things are a lot more bouncy and fun at 1/6th of
a gee.
That's about it for now.
Cheers