Thanks for your interest. My whole reason for creating pi-Stomp was to empower others to create something cool. I highly recommend you read the customization guide:
https://www.treefallsound.com/wiki/doku.php?id=customization_guideHere are some answers...
1. Is it possible to buy the PCB only? No. You cannot use any just any jack, pot, encoder, op-amp etc. and expect it to work as if the proper parts were used. I offer full support on everything I create/sell, but will not waste that time on someone who didn’t use the correct parts and do not want to encourage a useless piece of e-waste to be created.
I've found that most people who ask for a board think that I’m charging too much for kits because they haven’t done the math to calculate all the shipping and tax required to obtain the parts. Basically, the margin I keep is simply the discount I’m able to obtain by buying parts in lots of 100 or more and combining shipping, plus about $5/hr for my time maintaining stock and putting the kits together.
That said, if someone can tell me about their project and convince me they can build something that'll work without certain parts, I'll consider putting together a custom/prorated kit.
If you wanna try to create your own, that's cool, just know that I spent months and at least 4 board iterations before I got noise issues under control. The RPi power rail is noisy AF.
See the bottom of the customization guide for RPi pinout
2. Can other SPI LCDs be used? Yes. There is pi-Stomp firmware supporting various display drivers and aspect ratios. Most of the displays thus far are smaller so don't support all the content of the recommended display (240x320 ili9341). The one I've designed the enclosure around is a 2.2", but a 2.8" works great too with no hardware or software mods required. 2.8" is pretty easy to read from standing height:
https://www.amazon.com/gp/product/B073R7BH1B/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=13. Can other pedals be connected after the pistomp? Sure, it has adjustable line level outputs just like most effects. I wouldn't put a Fuzz Face after it, but...
4. How could one add a DI output and balanced outputs for PA systems? See the customization guide
5. What about headphone outputs for monitoring/readjusting on the fly by ear? Is it enough to have a switched jack to connect/disconnect the output signal to an amplification circuit? No, line level will not drive most headphones. But this little guy will:
https://www.ebay.com/itm/184214756448 Or if you use the AudioInjector Zero card, it has a 1/8" headphone output jack. In general though, I much prefer the IQAudio Codec Zero card and have standardized on it for future development.
6. Did I understand this correctly: There is no output buffer Most pedals i Know and have build have an output buffer. Why was it deemed unnecessary in this project? Built in on the DAC audio circuit? Why would line level output need buffering? It's already low impedance and higher output than most effects. I suppose some pedals might have a high-ish impedance output to emulate a guitar pickup, but I doubt many do that.