This tutorial deals with how to add a new squad member with a Name & Number & Hud-Slot. I would also recommend you check-out the tutorials listed below if you're new to modding:
REPLACING TEXTURES (
http://www.lucasforums.com/showthread.php?t=201998)
CREATING SHADERS (
http://www.lucasforums.com/showthread.php?t=201887)
CREATING RANKED TROOPERS (
http://www.lucasforums.com/showthread.php?t=202002)
CREATING NPCS
(
http://www.lucasforums.com/showthread.php?t=202003)
Go to the Squad Member of your choice and Right-Click --> New
http://img5.imageshack.us/img5/3295/step1y.png)
Now, type in the desired name of your new squad member. (NOTE: THIS WILL NOT BE THE IN-GAME NAME, IT WILL MERELY SERVE TO IDENTIFY YOUR NEW SQUAD MEMBER)
http://img696.imageshack.us/img696/9574/step2p.png)
Now, change the following values in the highlighted areas as indicated. (NOTE: YOU MUST SET bCANPREFORMSQUADMARKERS TO FALSE, OR YOUR GAME WILL CRASH. YOU HAVE BEEN WARNED)
http://img337.imageshack.us/img337/3707/step3f.png)
Next, open up the HIDDEN category, and scroll down to the bottom. Look for the SQUADHUDSLOT and change it to 4. (NOTE: SOMETIMES CHANGING IT TO 3 WILL ALSO WORK, AS UNREALED OCCASIONALLY READS SLOT 0 AS THE STARTING SLOT)
http://img72.imageshack.us/img72/6020/step4w.png)
Finally, Scroll up about half-way, and change the HiddenTag to the name of the actor, the HUDDescription to the number you want your new squad member to have, and HUDNickname to the name you want your squad-member to have. (NOTE: ONLY USE 2 NUMBERS IN THE HUDDESCRITPION SLOT, 3 NUMBERS DO NOT FIT)
http://img821.imageshack.us/img821/371/step5n.png)
Congrats, you're all set now.