Regarding my ideas for Aku, yeah, one of the first things I wanted to see upon seeing Bleedman's art was a PPGs & Jack Vs. Aku battle. To me, that would be leet.
As for the "Sword > Aku > PPG's" bit, well, I kinda thunk that the girls (Blossom in particular) would be relatively sweet and pure enough to hurt Aku.
Finally, with the Darkstar Council, yeah, my thinking was that, while Aku wouldn't team with them (He ruled a whole world by his lonesome, why would he want to share power?) he might either sneakily lure them to places where they could hurt the girls (annonoynous note: "be here 3:30 to hurt girls") or, while they fight the DC, he could surprise attack.