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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.

Three Questions:

  • 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.