3. If I ever manage to get Open2x out, we actually have patches to control the volume
.
Talking of which, are there any updates? Or is the project frozen atm?
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4. There is a button combo on the F200 to silence the boot sound on startup. Can't remember it off the top of my head though.
Keep one of the volume buttons pressed during the first boot screen.
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5. Try sticking a PSP dust cap on the d-pad if the separated buttons bother you.
Did you actually try that? I did and it didn't work in a satisfying way. I had to cut off the center "ring" (which originally was meant to make the button fit to the stick) and still it isn't working better.