2) with all the trouble and false trips after homing could there be a parameter to adjust the "axis" a set value away from the switch. "Home position off the switch" = .250" etc...
Maybe Mach has these features and so far I have not discovered them.
You either have a noise problem or bad switches, and moving farther off the switch won't help.
It is possible to do, however. In Config >Homing/Limits, there's a Home Offset column to set the location of the switch in Machine Coordinates. You can modify the homing script to move wherever you want after the homing process has completed.