I'm just wondering if theres a way to save a sims look after you already make them and bring them back into edit in CAS?

I've been wondering that too! I always want to save the "pre-made" heros but can't

You can however use the CarryOver Sim option... and you would see in your save's folder (in My Documents or Documents folder for Vista/7) a folder called "CO" and there is a .sim file, rename it and move it to SavedSims folder and you can use it when you create a hero as "Saved Sims"

can you code? I can give you a source of my View Inventory and integrate the CarryOver interaction in it or use grim's medieval core...