If you're using Rawr to weigh your gear and feel as though you've reached the amount of stamina you require you can ignore the survival numbers and sort by avoidance and mitigation. The overall bar for each piece is broken up into three catagories by default and you can edit these.

With regard to stat weights you should refer to tangedyn's spreadsheet @ http://goo.gl/7jIJw

I've been putting together an offset for Kitty and Rawr is stating the optimal rotation includes running out, Feral Charge / Ravage!.
Is this the case at higher gear levels?
Is this only the case at 80%+ health?
Dummy testing has proven inconclusive for me. Ravage hits hard, but the overal dps doesn't seem any better.

I have been playing around with similar tactics on the targeting dumby, and have gotten similar result to you. The DPS increase overall is minimal, if present at all. I have limited raid experience at the moment, but so far the first few bosses in BWD require frequent target changing and sometimes have large movement requirements. So while the backout and charge is a small increase in simulation on a single target, having your charge off CD to use on target changes, returns higher reward in actual raid content, or at least it has for me. (Keep in mind, this kitty has experienced only the Tron and Magmaw encounters, thus far).

There are plenty of bosses where you can be in melee range but still far enough away to feral charge due to the bosses massive hit box. Argaloth is one I have noticed this on in particular. So certainly the stampede can be a definite DPS increase in some situations.

I believe the poster was talking about bear form (hence using savage armor kits) and not cat form. In which case yes, you can expect about a 20% miss rate. It really can suck early in a fight, but most of the time it doesn't end up mattering past 10 seconds into the fight. Vengeance and high damage are pretty insane right now.

If you think about it, it doesn't take long to get 8 yards from the boss, about a second, so while running out you will lose one or two auto-attacks. In place of that you will gain a hard-hitting ability that will give one or two combo points, while only costing 10 energy. It is a DPS increase, but only if you don't hesitate while doing it.

How much extra armour is that going to give a typical bear?

(Or, I guess as may be more useful at a glance, what kind of mitigation % change will it give, especially compared to other tanks?)

Keep in mind this is pulled from the data mined patch info off of MMO. I doubt that they are going to give us an increase that gigantic without putting it in patch notes. Should check the PTR to make sure.

Chip, one thing you're missing is that Primal Madness is pretty weak for DpS, and not too great for tanking either, at least if you're concerned with raid bosses. So change those points into Blood in the Water for better DpS imho. A good in-between choice is Talent Calculator - World of Warcraft

I ended up at 42.5k armor in mostly i346 gear, gaining some 11.5k armor. A guild mate in about the same level gear has 39k armor on live as a warrior, so it's not far more.

I was for fun watching what relative stat values come out highest on threat. Exp/hit nr1 and 2 ofcourse, but strength is shown as nr.3 with agility as nr.4.

In what way is strength better than agility? Because i can think of none.