Question, does 5th ed. work on basically the same principles/numbers as 4th? I know you said 6th had some major redesigns...
There's very little difference between 4 & 5. Having trouble remembering what they were to be honest. I think they adjusted some power costs and the some of the power frameworks. When 5th Ed came out I started moving element into my game straight away, without any problems.
6th edition changes some of the characteristics (drops COM for example) and changes the costs and also drops figured characteristics. If you go to the Hero System forums
you will find details about upgrading to 6th. They are almost as friendly there as here
If you are looking for Hero System frameworks I created what I call a Light-Weight Framework for 5th
and nolgroth has a More Complete 6th Ed framework
I never used the CharTool for Hero System though, since I prefer to create heroes on paper with a pencil