After trawling through numerous websites as well as hitting up the Wayback Machine more than once I found the information you were looking for. This is the best/most accurate information I can find short of buying the books and looking them up in the books themselves. Most of this information by the way came from the Wayback Machine archived pages of the ...
If you haven't already, take the Iron Will feat...it increases your thresholds for both subdual damage and stress damage. A longer-term solution is to get 4+ levels in the Brawler expert class to also add to those thresholds. The Explorer class and some unarmed feats also provide some ways to up your CON score or increase your threshold.
I'd still look at ...
The Feat Doesn't Provide Free Stuff
The Benefit of the feat Micro-miniaturized (Spycraft 2.0 197) says
When you build or request a gadget, each Mechanism is 1 size category smaller, and you may include 1 additional Mechanism per gadget.
No mention is made of how to include the additional Mechanism therefore standard rules apply. The feat Micro-...
For all three of your questions, the answer is the same:
A hacker's master key ability doesn't help him create codes at all. Decreasing a code's Power Rating doesn't do anything to change the DCs of the hacker's Science (Mathematics) skill check needed to create a code.
It's a hole in the rules--an annoying one, given how tightly ...
You could use Miniaturization, so that your belt buckle projects some sort of force field.
The Proteus mod is great for things that transform into other things, which to me always felt like a vehicle kind of property.
In a way it's realistic: armor looks bulky, or makes noise, or sticks out.
There are ways to deal yourself stress damage
None will be very dignified.
Go skydiving (pp. 108-9). Accumulate all the stress damage you need via failure; accumulate significantly less on a success.
Spray yourself with a flamethrower's igniter fluid (pp. 313-4). Pro Tip: Do not do so near an open flame.
Get blinded and stunned by a flash/bang grenade (pp. ...
The second, far more hazardous scenario is correct.
If the agent's stress threshold is exceeded, the agent makes a Willpower saving throw each time he's dealt stress damage
This is confusing because when initially introduced it sounds like the saving throw is made only upon gaining a new threshold. Spycraft 2.0 under Stress and Subdual Damage Thresholds ...