"I signed up for the cheapest (RBC Centura) account which is free with $700 US min. balance in your account."
That's the one I got, too. I keep $700 in there, doing nothing (I call it my "rainy day fund") and I've never paid a cent of fees. Unlimited transactions, free cheques (which I've never used anyway), debit card, and the offer of a Visa (which I declined). I think it's worth setting aside $700 to pay nothing in fees. If you're an accomplished investor, you could probably take that $700 and make more than $6.95 a month with it, and then pay the $6.95 monthly fee with that... but I'm not. 🙂
"I need to sign the form (W-8BEN) and return it to them."
I ripped up that form and recycled it. I emailed my Centura rep and he said not to bother if it doesn't seem like it applies to me. It didn't apply to me. I've had my account a year and never heard anything more about it.
"I can't transfer funds at this time. I signed in online banking and found out there's another step---they will mail me an activation code. After I submit the activation code I can have full access. Now I can only view my balance."
I went through EXACTLY what you're going through. I was annoyed at the initial delays because I was impatient to get my money transferred. 🙂 But it has been very, very worthwhile.
"After HSBC sent me the package I have to sign a whole stack of papers, plus include a certified cheque and a reference letter from my current bank and 3 months of statements. That costed me $7 and $16.50 respectively from my bank."
That sounds very unfortunate. I didn't have any of those steps (or costs) with RBC Centura.
"Also I started using XE and found out that they took about 1% out compared with their median exchange rate. It's better than PayPal and most banks but I am not sure if it's better than most money exchangers in the local market."
XE.com guarentees that they will beat any price, so I'd look into taking them up on that if you think they're overcharging. So far I've never found a bank, PayPal, currency exchange shop, or online company who will beat their exchange rate... but if you find one, do let us know!