1. Yes, the Find and Replace Window determines the minimum width of the CodeView window (even when hidden). The scroll bars and title of the other Windows determine their minimum width. Just opening a new epub with a different title can change the layout.
So that is expected behaviour. If Sigil takes up too much space on your screen, try either hiding the dockwidgets you do not need or use fast virtual desktop switching.
2. I will test this on my machine. But there was no code change in Sigil since the previous version related to this. I assume by "custom button" you mean an icon on your clips bar?
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