I love teaching The Crucible. It's always one of my students' favorite works. We teach it to juniors at my school in an American Lit. class. I've tried all sorts of activities with it, and most of them have been successful. I have Crucible flashcards which help my lower level students with the characters. They add information to the cards as we go through the play. I also have a flipchart for a connections activity. One of my students' favorite parts is when I divide them into two Puritan communities. They elect a minister, several councilmen, etc. During the unit, they watch for sins (students come up with a list of sins) or suspicious behavior in their community members and point it out publicly.
I also have a copy of an article entitled "Spellbound" which tells the true story of a high school girl who was accused of placing a hex on one of her teachers. It's a very effective tool in showing students how easy it is for humans to get into "witch hunts."
In reply to #5, I use the film version each time I teach the play. We usually read through and analyze an act and then I show them that portion of the movie. It helps build suspense and for general level students, it provides a great visual. On my copy of the DVD, Daniel Day Lewis gives a brief interview about the complexities of John Proctor's character, and that helps my students with literary analysis.