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Redmud,
You may want to go back and look at my post on the freeware question you posed. I listed a bunch of hacks there that I use.
My favorites:
MenuHack (opens the menu bar by clicking on the title of the app. This one is the all-time best hack ever)
AfterBurnerIII (under and overclocks the Visor)
Keyb+Graffiti (lets you use the virtual keyboard and graffiti strokes at the same time)
You can use the freeware EVPlugBase instead of the shareware HackMaster to manage any hacks you have installed. It works great and I've had no problems at all.
As far as the voltage stuff goes, I'm on my second set of batteries (Duracell alkalines) and I'm using the battery meter functions of LauncherIII to show me the existing battery voltage. It seems to be pretty accurate although the meter does jump due to temperature differences. There are hacks out there that can modify the voltage/meter levels for different kinds of batteries (NiMH, NiCad, alkaline, etc...) but I haven't tried them yet. I just change the batteries when the Visor tells me to, not at some arbitrary level like 2.4V.
Mark
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