I was recently in Europe, with wife and 2 TMob Vibrants...
I put in UK orange SIM cards, but mostly trying to use WiFi calling.
Nimbuzz+nimbuzzout seems to work very well, great sound quality, but cannot leave it on due to battery drain, and no number for folks to call you (though there is if I use sipgate with it).
Truphone has decent call quality, not as good as Nimbuzz, people on receiving end complained of echo,
but you can leave it in background all the time with minor extra battery drain, and people can reach me on wifi using my US number.
And yes, turn off roaming, auto sync, background data, and set email check to manual. Ought to be an easier way to do all that (there is some ap, I've heard...)