Hey, Piko, glad to see you around again. Although your avatar still scares the hell out of me 
Let me see if I can help you:
1. Adding horde units to a faction:
- Open the EDU file. Select the unit of which you want to make an "horde version". For instance:
Code:
type yuezhi horse archer
dictionary rtr_bactria_horse_archer
category cavalry
class missile
voice_type Medium_1
soldier yuezhi_horse_archer, 24, 0, 7.4
mount light horse
mount_effect horse -3, camel -4, chariot -4,
attributes sea_faring,hide_forest,cantabrian_circle,hardy,no_custom
formation 3, 4, 6, 6, 5,square
stat_health 1, 0
stat_pri 4, 13, arrow, 130, 15, missile, archery, piercing, none, 25 , 1
stat_pri_attr thrown
stat_sec 3, 15, no, 0, 0, melee, simple, piercing, knife, 0 , 0.8
stat_sec_attr no
stat_pri_armour 1, 12, 1, flesh
stat_sec_armour 0, 0, flesh
stat_heat 0
stat_ground -6, 0, -6, 1
stat_mental 14, normal, untrained
stat_charge_dist 40
stat_fire_delay 0
stat_food 60, 300
stat_cost 1, 450, 250, 104, 112, 720
ownership thrace
You just need to change three things. I will underline them:
Code:
type yuezhi horde horse archer
dictionary rtr_bactria_horse_archer
category cavalry
class missile
voice_type Medium_1
soldier yuezhi_horse_archer, 24, 0, 7.4
mount light horse
mount_effect horse -3, camel -4, chariot -4,
attributes sea_faring,hide_forest,cantabrian_circle,hardy,can_horde,no_custom
formation 3, 4, 6, 6, 5,square
stat_health 1, 0
stat_pri 4, 13, arrow, 130, 15, missile, archery, piercing, none, 25 , 1
stat_pri_attr thrown
stat_sec 3, 15, no, 0, 0, melee, simple, piercing, knife, 0 , 0.8
stat_sec_attr no
stat_pri_armour 1, 12, 1, flesh
stat_sec_armour 0, 0, flesh
stat_heat 0
stat_ground -6, 0, -6, 1
stat_mental 14, normal, untrained
stat_charge_dist 40
stat_fire_delay 0
stat_food 60, 300
stat_cost 1, 450, 0, 104, 112, 720
ownership thrace
We have: changed the name of the unit, added the can_horde attribute and reduced the upkeep cost of the unit to 0. You must do this for each unit that you want to appear in the horde. After doing this, your game will not work 
2.Making the faction able to horde:
1. Open descr_sm_factions. Look for the faction entry and add all the stuff that I write in black:
Code:
faction thrace
culture nomad
symbol ../77bc/data/models_strat/symbol_thrace.CAS
rebel_symbol ../77bc/data/models_strat/symbol_greek_rebel.CAS
primary_colour red 255, green 255, blue 141
secondary_colour red 255, green 255, blue 141
loading_logo loading_screen/symbols/symbol128_thrace.tga
standard_index 19
logo_index 249
small_logo_index 262
triumph_value 5
intro_movie fmv/intros/greek_intro_640x480_bars.wmv
victory_movie fmv/victory/greek_outro_320x240.wmv
defeat_movie ../77bc/data/fmv/lose/illyria_eliminated.wmv
death_movie fmv/death/death_thrace_sand_320x240.wmv
custom_battle_availability yes
horde_min_units 60
horde_max_units 100
horde_max_units_reduction_every_horde 20
horde_unit_per_settlement_population 300
horde_min_named_characters 4
horde_max_percent_army_stack 80
horde_disband_percent_on_settlement_capture 33
horde_disband_percent_on_settlement_capture 50
horde_disband_percent_on_settlement_capture 100
horde_unit yuezhi horde noble horse archers
horde_unit yuezhi horde noble horse archers
horde_unit yuezhi horde noble horse archers
horde_unit yuezhi horde horse archer
horde_unit yuezhi horde horse archer
horde_unit yuezhi horde horse archer
horde_unit yuezhi horde horse archer
horde_unit yuezhi horde horse archer
horde_unit yuezhi horde horse archer
can_sap yes
prefers_naval_invasions no
The only thing that I modify here is the horde_unit lines, in order to add the new units that I have created in the EDU file. I guess that the other parameters can be modified but, to be sincere, I do not think that they have a great impact in the game.
3. Other things: you need to copy some files from vanilla BI to your UI folder:
BATTLE3.RSD
SHARED2.RSD
STRAT3.RSD
4. Enhancing your mod: in the descr_banners file, add a line for the horde symbol to appear in the banners of the faction in the strat map:
banner_horde 0, 0, 1, 1, bi/data/textures/#horde_symbol.tga
Concerning the no-borders for the slave faction, as Florin told me, make the faction's primary and secondary colour the same in descr_sm_factions.