was wondering if there was an easy way in DS to add new channels for morphs to a figure not set up with empty channels?
Yes, it could be scripted - pretty easily, actually. But of course it would then need morphs created to use the channels - they are static, that's why sometimes two add on morphs won't work together as the second loaded replaces the first (which was part of the reason for the ExP system in the fourth generation figures).
i always wondered about that. i've come across community morphs that go into the upper number channels.