Zero does not equal no sound. – Many pedals do not go “completely quiet” when the volume is at zero.
Should the Volume Knob at Zero be louder than unity gain as you described above… No.
- When your Volume is at Zero and you rotate it up full does it get extra loud or softer?
- Is there tape on the back of the dual-gang pot?
- R7 = Blue, Gr, Black, Br, Br
Next check and verify all capacitor codes. Once you have verified all capacitor codes then re-flow all solder joints to be certain there are no cold solder joints causing the problem.