I'm going to go ahead and disagree with you about flaxbeard being useless. It's just mostly useless. However, the armor is quite good, and will give you flight fairly early in the game. With golden plates in mine, I was really racking up the xp too. And it never takes damage!
I use armour from Falling Meteors and Adventure Backpack. The traveller's boots give step-up and 2 full shields of protection, the carbonite body armour from the starting chest has plenty of bonuses, and I have a meteorite helmet for attracting drops. I haven't got a solid preference on the leggings yet. None of it is from Flaxbeard. The MyFit also grants several bonuses that help with mobility, which (in my honest opinion) generally acts as a better defence than just tanking hits. If the enemy can't reach you, you don't have to worry about damage. Flight is always nice, but I'm going to wait until other options become available.
I really can't agree with this. I'd begin by saying that efficiency doesn't necessarily matter - sometimes it's just fun to set these things up and look back on what you have designed with a sense of achievement. I have a boiler room and brass pipes running through/along the walls and ceilings of my underground base, and that just looks awesome.
You say the mold is useless because you can use a crafting table instead, but I think you may not have realised that the mold is actually much more efficient for producing brass (4 ingots for every 3 copper and 1 zinc, plus it can accept smashed ore, suitable ingots and dust). I'd strongly recommend using it rather than the crafting table for brass production (better yet, try to make it automated - you can use redstone to control the crucible in one of the recent updates!) What I would agree with you on is the ratio of copper to zinc required is too high - because zinc has basically no other application, I find I always have it in excess, while copper is in higher demand. Perhaps a better way to resolve this is to change ore generation a little?
I never really used the rock smasher, but I thought it was really intended as an early-game cobble/gravel gen (or sand/dust if you can place the blocks automatically too). Again, I don't think the inefficiency matters - by that logic, I could argue that in vanilla minecraft, tinkers' construct is useless because it's faster and less resource-demanding to just make a diamond pickaxe.
The steam exosuit is actually a lot of fun, though graphically it has a few problems. The jetpack is cool (although the novelty wears thin after a while), but I most enjoy combining the other buffs along with those from botania accessories. I also found the mod useful for setting up an automated charcoal farm (along with steve's carts and buildcraft pipes) - the cart chops down a tree, the logs are put into a furnace, the furnace is powered by steam heaters, the charcoal is removed and some is used to keep to boiler fueled. Also, the archimedes screws allowed me to pump water from an infinite source, so I can supply water all over my base to any device that uses it. I'm sure that are ways to do these things using other mods, but it doesn't change the fact that I enjoyed setting it up and am pleased with the result.
As a final point - even if you really can't enjoy flaxbeard's steam power, you only need to produce brass ingots for galgadorian. You don't have to have a boiler if you don't want one, you don't need to bother with rock smashers and exosuits if you have better alternatives... There is no reason to remove the mod from the pack entirely unless it is disrupting our experience with the rest of the game, and galgadorian is the only way I can see it doing that. I truely don't think this mod needs to be removed or changed in its current state.
I personally find Chisel, Carpenter's Blocks and MicroBlocks are overall the better option for decoration. They demand less resources, are far more versatile, and over a hundred different blocks (not including MicroBlocks) can be produced without ever having to leave your base, especially once you have a mob farm set up. Brass pipes demand a lot more and give a lot less.
For whatever reason, I couldn't get the crucible to accept copper ingots. I'll test a couple of other sources of copper just to see if I can get more out of it, but if Galgadorian needed any metal besides brass, I wouldn't bother. Thanks for the tip about automating the crucible. I really don't want to spend hours literally pouring over brass. (Yes, I know it's supposed to be "poring over" in its normal context.)
Regarding the use of the rock crusher as a way to make sand and gravel early game, that's what I used hammers for. As far as automation goes, I haven't set anything up yet, but I'm going to try BC Dusters. The later tiers will hopefully run on RF from lava generators. I got a constant steady supply set up there already.
As far as your point on the diamond pickaxe goes, that's a straw-man argument. I'm talking about how the raw resources are gathered - a guaranteed return of 1.5x in the smeltery vs the chance of 1.25x return from the rock smasher. Your argument refers to the process of making tools (in a different world no-less), not the process of obtaining the highest yield from ores. There's no comparison to be made.
The steam heaters in your description of charcoal automation just sounds like an optional extra -- Steve's Carts and possibly BC Transport do the job just fine without them.
I don't have a need for water automation. Correct me if I'm wrong, but from what I've seen so far, boilers seem to be one of the few things (if not the only thing) that actually requires it.
I haven't pursued any means of flight yet because I haven't needed to, but I know there are other jetpacks. I might even check Botania for a mode that doesn't require a recharge station of some kind.
Finally, I'm glad someone is getting some fun out of this mod, but it practically feels forced upon me simply because of Galgadorian. That, and the fact that I just can't leave a quest line unfinished. -_- The pack needs more options for progress.
Flaxbeard's is really the only option for early game water automation too. Unless you luck out and get an iron pick right away, of course. My current world uses mekanism pumps, but ugh, galgador.
I take it that iron pickaxe is for the mining well and then the subsequent pump? If so, I agree. If nothing else, the recipe for the mining well could have been changed to make it possible without relying on random drops. But what do you need water automation for? That's not a rhetorical question, I'm genuinely curious. The only time I've used much water outside of the exploding boilers is for magnesium, and again, that was a one-time thing for the sake of a couple of random quests.