How od you make a .cha file?
You don't need to, as it's just a format exported by agsedit, in case you want to share your characters with others or save it for other future projects. You cant make a .cha file with any other programmes out there.
If you want to make a character, just 1) draw it and save it as BMP/PNG/PCX graphics, 2) import them as sprites, 3) make views with the sprites, 4) assign the views to characters. All of these were already covered explicitly in the manual.
EDIT:
/me LOVES typos!
thanks
Please, please please, read the Beginners FAQ!