ONE
I'm browsing the ally spirit rules (trying to find out where its personality gets decided e.g. is it perky, does it like to play boargames, does it enjoy teasing its summoner, is it male/female, etc, etc) are there any rules about that is or completely up to the player when they make the spirits formula?
Partly up to the player, mostly up to the GM. The 'mentality' of an ally spirit is one of those tricky things, in game. Their personality, likes, dislikes, and so on are buried in the formula, certainly, but that's the same as saying the way your mouse moves across the screen is buried in your PC's operating system. Where, in all those lines of code, are you going to find it to edit it? Sometimes allies are similar to their summoners, sometimes they are polar opposites. And sometimes they are manifestations of their emotional state at the time of summoning. Regardless, they aren't cardboard cutouts.
TWO
I noticed the ritual of change is twice the original cost i.e. summon an ally spirit base cost is 8 karma per force, enhance it later its 16 karma per force. So I was wondering does anyone know the reasoning for why the cost doubles? Right now it seems you'd be better off waiting until you'd saved up say 48/50 karma for a force 6 ally than paying 24 now for a force 3 then 48 to enhance it to force 6 for a total of 72 karma or 26 karma more. Because adding other abilities skills, spells, forms don't suffer the doubling so you can add those later for the same price you would if they were part of the original formula.
Honestly? Because their Force plays into their limit for most things, and there is no top end on a spirit's Force, really. That can get nasty, very fast.
THREE
It say's dieing or nearly dieing free's the spirit if you've treated it as a friend, looked out for its interests, listened when it tells you something (doesn't have to be plot related could just be that it wants to see a particular movie so you go together as friends) could it remain as a free spirit that regards you as a friend? The important part is it wanting to continue your relationship I assume force 6 and above is likely to become a free spirit while a lesser force one would probably return to its metaplane. For that matter what is nearly dieing, is there a game definition soewhere or is it up to GM discretion?
Anything that sends you into Overflow, or where you have to burn Edge to survive would count as nearly dying. And yes, if you've been a friend to the spirit rather than a master, they may continue to be your friend when freed. But that's totally dependent on the roleplay.
FOUR
You pick its metaplane and it can be destroyed by a trip to said plane so are you required to pick a metaplane from the pick or can you choose some arbitary plane that has relevance to your character e.g. Niflhelm for a norse mage or Elysium for a greek one as its home plane? Obviously you can't make up something completely ridiculous e.g. the Plane of DC where superheroes live in an alternate earth.
You can pick whatever plane you like. There are a near infinite number of metaplanes out there.
FIVE
Can an ally spirit be a a greater spirit? efore anyone acuses me of munchkinism this is purely curiosity I want my ally spirit to be a spirit of man and materialization so even if she was a great spirit she'd get magical guard so she can use counterspelling which I can give her anyway.
Different progression tracks. Invoking a greater spirit is a different path from summoning an ally spirit.
SIX
How realistic are the materialization ally spirits. I don't mean in appearnce here but in all the little things that are part of being human do they eat, sleep, get annoyed with you leaving the toilet seat up?
They might, or might not. It all depends on the spirit's whims, personality, and the master's attitude in turn. They CAN eat and sleep, though they don't need to.