Great ideas! That is what I love about this community... everyone shares their ideas and we take a little here and a little there and we create our own games out of the shared creativity.
I gave up the idea of card creator possibly for that very reason (the idea of it is great but possibly needs an update). I use Paint.net (which is not as fancy as photoshop but its FREE!). I also recently discovered it's pretty easy to import free plugins into Paint.net that give it a lot of extra features too, including opening up PSD (photoshop) files.
I am all for Skill cards for different hero classes, especially after the players have gotten some seasoning and want more variety (can't let the Wizard have all the fun!). Younger players or not used to these types of games may prefer the simpler basics.
My solution to the "I ran out of spells!" complaint is to basically give opportunities to find spell scrolls (using Sjeng I believe had this idea) where you find a Treasure card that gives you a random draw of Spell Scrolls. I let the furniture be more interactive... if Wizard searches the Sorcerer's table I let him recharge (or recover you could say) one used spell. This is only once per quest. If he hasn't used up any spells, then he gets a random spell scroll card.
Same with weapons... Weapons rack is an Equipment deck card (unless the quest treasure is specified instead). Of course now that I'm using the "one search per room, per player..." (so up to four searches per room for treasure) that means a lot more cards can be drawn potentially. Make it harder by taking out some of the good cards. And you can either use up the cards, or shuffle them back into each deck, so another person could get them again on the same quest. Four battle axes? Maybe I won't be that generous!
Alchemist's Bench will be where Searching for Treasure gives the Wizard or Elf a chance for a Potion... draw a Potion card. But it might be poison!
There are so many cards! But I am getting off topic. For my warriors, they have the Combat Cards to use, but with your system, the Barbarian himself gets his own special skills which I think is neat. In my system, the Dwarf can disarm traps easily, and the Barbarian is just "he-of-the-many-hitpoints." Everybody else either gets some spells or skills. But I still let my Barbarian and Dwarf draw Combat Cards, so everybody gets something, and as they complete more quests they can get more. I give my Barbarian stronger rolls with swords or axes (black dice) and let him draw a Combat potion, and get an extra Combat card, but nothing too complicated. The player who is looking for a character without many cards just a lot of body points so he can survive in combat will tend to pick the Barbarian. But he doesn't have to be boring, either! As they build confidence, introduce more options.