I am not at all surprised by all the problems you've encountered with the HOT-433 board. The IDE/HDD stalling during Windows 2000 bootup was a problem I ran into some ago as well. Running your IDE controller on IRQ 12 resolved this issue? Curious. You mentioned later that the issue was further resolved with a BIOS hack to fix the IRQ routing table. Did you use Awdbedit? If so, what was the routing table before and after the hack?
You mentioned this BIOS hack a few times in the thread, but I could not locate your BIOS file uploaded to the thread. Did I miss it? Does your BIOS hack implement mkarcher's hack for getting the Matrox G450 working? Was the PS/2 mod added to the BIOS hack as well?
If you are looking for DVI on a PCI card that works on a 486, you may want to consider using the Matrox G200 with the MDR-20 flat panel add-on connector. You can then use a MDR-20 to DVI cable adaptor. This is what I've done on my IBM 5x86c-133/2x system.
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The attachment MDR-20_to_DVI_cable.JPG is no longer available
Did you try EDO memory? I recall being surprised that this board works with EDO.
I see you've added USB to your 486. Check your Windows benchmarks with and without the USB card installed. When I ran these tests, I got a lower CPUMark32 score with the USB 1.1 card installed. I think the performance drop was in the 5-20% range.
Nice to see you got the PS/2 mouse working on the HOT-433 v1-3. This was on my ever growing list of things to figure out. Has there been any work getting the PS/2 mouse header working on the HOT-433 v4?
Plan your life wisely, you'll be dead before you know it.