3. I make new PCB's, yes. I have designed several different boards based on different configurations of RAM/ROM. Each one of them was designed with the idea that I can only use "new" and "commercially available" components. See:
The first board is my design with 2MB's ROM and 256KBs battery backed SRAM. With the use of a jumper located in the top left, the user can change the mapping of the board to just 1MB ROm and no SRAM.
The second board is simply a 1MB ROM with no SRAM. The special thing about this board is that it uses two 8-bit ROM ICs rather than one 16-bit ROM IC.
Both of these boards are reprogrammable via the cart edge.