If anyone has any tips for the most cost effective way for expats to file, please share them here.

I'm doing it all by hand because I'm tired of going through the 'free' apps and entering in all my details, and when I get ready to file it end up being hundreds of dollars to file since the other forms (extra 1040 schedules, 2555, etc) are not included.

yes. and you have the right answer. download and print forms. no way around it. or pay $500 each year to the top 2.