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I think for what you want, this section is all you need to pay attention to. It shows passive splits and mixes.

Yes, you would need a stereo blender, or just two separate blenders. Are you sure your rotary pedal is really true stereo? Sometimes stereo pedals have 2 ins and outs but are mixed to mono and then split again?

So you want to send a left+dry to one amp and right+dry to another, and control the mix for each side independently?

This is what did it for me.

RTS is the same as TRS but with the tip and ring switched. Some expression pedals use that order but in this case I don't think it matters since the return jack just "merges" a stereo signal to mono.

Do you mean the Tru-Loop? The manual says it has an RTS jack, not TRRS. I don't see any reference to anything called Tru-Blend

"thicker, more saturated" sounds like a big muff to me

Looks like a bird took a shit on it. 😁

What's the subject?

Yes, but switches can be Normally Open or Normally Closed so it depends on the the configuration of the jack. You can have different combinations of NO or NC in a single jack. To be clear... a TRS jack is not a "switched"jack. There is not a switch built in to it, but it can be implemented as a...

Switched means it has a line disconnect built-in like the second picture. A regular TRS jack is unswitched which is what the first one is. The third mega one has two switches, one for tip and one for ring.

Not sure. I bought it used.

This midi foot switch has glue and tape for the front screen, and they mounted the PCB to the bottom so the screws don't show on top

This is the inside of the new Maestro enclosures. They glue and use standoffs

I've seen people rough up the inside of an enclosure and use hot glue around the edges of a screento hole it down, or alternatively JB weld standoffs in place and use screws to clamp down on the edges of the pcb

I've had a couple of mix ups but nothing that was a deal breaker. They always made it right. I think it's just growing pains.

I don't think I've ever seen a buffer in the power section. Why is the opamp even there?

R12 sets the input Impedance for the Rat2 at 2M2. It was omitted on the Rat so not sure what the impedance is for it. That may account for some of the difference.

I just cut thru one of the sockets and trim the edges

Millmax makes a bunch of press-fit stuff like pin receptacles. I havent tried but any but one of them might do the trick https://www.mill-max.com/