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1) no risk, no point.
The internal memory still gets used for app cache. It will fill up too, possibly not letting you go beyond 512 by much anyway.
You could repartition your internal space to give more internal memory but this is for advanced modifiers only. See how you get on first and revisit this idea if needs be.
Formatting to 1GB on advance can'thurt, you just won't be able to use it all yet
2)move them back
3) no idea. I advise backing io content before doing this anyway
(other than of course going back to my stock rom via nandroid.)Yes its usually data related. system settings for incompatible system apps that sort of thing.
if you take a titanium backup, it backs up your apps. But also your settings.
If you have a sense rom, it backs up settings for lets say, sound. If you restore those settings on a non-sense rom, its restoring settings on a different sound application (a different version or whatever) that is incompatible.
When you reboot android, it tries to apoply those settings at boot, but if the settings are incompatible, it can prevent android from booting.

Link to ROM please?
An app isn't just one file, and not all of it is moved. With gingerbread the "move to sd" moves an element which most a2sd scripts (and the move to sd option in froyo) do not move. For some apps this is small or nonexistent, but for a few it is noticeable, and angry birds is one if those.Another app for example:
Angry Birds. Total size 18.77MB
Free Internal memory when app is on Internal Memory: 65.93MB
Free Internal memory when app is on SD: 67.66MB
I don't understand it...
There are 2 versions of that rom. One with a2sd+ and one for CM7 hboot. Are you sure you have the former and not the latter?It's an RTL fixed variant of the InsertCoin v20 Rom: [ROM][7/05][Sense2.1+Sense3.0 GB]InsertCoin CM7/STOCK v20 - xda-developers
The thing is that the script's behavior is inconsistent, some times it works perfectly some times it doesn't.
Another app for example:
Angry Birds. Total size 18.77MB
Free Internal memory when app is on Internal Memory: 65.93MB
Free Internal memory when app is on SD: 67.66MB
I don't understand it...
There are 2 versions of that rom. One with a2sd+ and one for CM7 hboot. Are you sure you have the former and not the latter?