Thanks for that detailed workflow. Even though I don’t use Blender (I use Modo), I can definitely see the value of these features. It seems that it can be, as you said, a pain in the ass, and imperfect, but IMO if you find a workflow that you like, and practice it, it will be faster than if you would have racked your brain trying to figure something else out. Good luck and I can’t wait to see your video/tut.
On a side note, I understand where the confusion comes from different terminology. What you are describing (shape keys) is called morphmapping in Modo. Something I avoided at all cost when I was learning the app because I didn’t have a clue what it meant. Once I realized they were blendshapes, I was like “Ohhhhh”. Then I realized that there was a whole load of functionality all rolled into one menu, called vertex maps. Essentially, anything that uses vertex information and point order (such as UV’s, morphmaps, weightmaps, etc) falls into this category, and now I can’t live without it 
-Rage