I'm hoping I can copy a file over from 1 character account to the others and go from there.
what about bar setups?
Also, I'm running 1 22 inch widewscreen in 1680x1050 and making all 4 even makes it hard to operate on all of them, where as making the main big and the rest small makes it impossible to operate on 3 of them. Any suggestions to fix that?
There is a macro file in the WTF folder for each account. You can copy this.
Bindings and bars are a lot trickier. It depends if you use an addon as well.
For example, my entire wow crashed last night, I lost everything and had to end up deleting the WTF folder. 7 accounts, about 25 characters total took 3 hours to re-setup. It is a lot of work. But it is work that you will only have to do rarely so I would recommend taking the time to do it by hand and make sure it's correct.
Depending on how you play, I operate my copies of WoW stacked on top of eachother. At any given time I can only see 1 and it's running at 1440x900 windowed on a 1680x1050 screen. If you are operating only the main and have the other 3 followers, I am not sure what you would need to have them visible on the screen. Just switch between active copies of WoW when you need to switch chars.
Oh damn, how do you do that with maximizer?
The only program I run is hotkeynet (or keyclone if you prefer that one). Nothing touches the WoW windows itself (except to rename them).
But like I said, it does depend on how you play. Keybinding, mods that auto quest accept, a follow mod and so on are all essential, as you don't really ever want to look at the other characters.