If I start with CW010 Donald Blake, but end up replacing him with CW038 Thor, how many victory points does my opponent get if he KO's Thor? The full 200 pts? That doesn't seem very fair for the rest of the folks in the tournament....

The orange starting line is worth 33 points.

From page 6 of the rulebook under REPLACING CHARACTERS:
If there are any other or future rules questions, you may send them to [email protected].

That's exactly the section of the rules I was wondering about. So if the replaced Thor gets KO'd with his measly 2 clicks, the opponent gets 200pts. Yeesh! Doesn't seem like a good idea to replace to orange line figures (or at least this particular one).

No, they score the cost of Donald Blake

"...award victory points equal to the point value of the replaced character that began the game on your force, unless the value of the replacement character(s) is higher."

The replacement figure in this case is Thor, who is coming in at his 33 point, orange line NOT his 200 point green line.

But how do we know he is only 33

Because the effect specifically tells you to bring him in at his orange starting line.

Sorry I misunderstood. For some reason I thought he was saying all orange starting lines are 33.

If you look on the dial for any figure that is AEed from a cheaper click, it has an orange number next to their point cost. That number is there to help represent how many points they get when they start at that level. It is simar to playing a figure at a blue or yellow level when their highest is a red: you score what it cost to play the figure.

Thanks for the clarifications! I didn't see the orange line starting points in the Units section, but saw them when I pulled out my cards.

Victory Points: When one or more characters replace a character that began the game on your force, and all replacement character(s) are KO’d, award victory points equal to the point value of the replaced character that began the game on your force, unless the value of the replacement character(s) is higher. - pg. 6 2014 Rulebook.

So, as an example, if the replacement character was higher in points than the original character (original = 50pts, replacement = 60pts), we would score the replacement (60pts)?

If the replacement was lower in points than the original character (original = 50pts, replacement = 40pts), we would use the original (50pts)?

So basically the higher point character? Is this correct?

Correct. If a replacement character and the replaced character differ in point value you score the higer of the two values.