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  • Does the SD card work over software SPI?

    That's the plan - I see no reason why it shouldn't.

    ESP8266 layouts

    Yes... I think the most popular will probably be the pinned one, which is what I'd do initially I think.

    Castellations

    I've had a look at this and yes, I think it can be done without increasing the board size. Not it just comes down to whether the PCB manufacturers will do it without charging a load extra.

    As you say, shorts might be more of an issue, but it's probably not good practice to leave the board floating around uninsulated anyway...

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