1. For the online application, you can fill it or, but I would just put her email address in, since it’s her application. The biometrics appointment is booked as part of the online application and then you print the confirmation - which may be on the website.
The direct link to the online application is here (your link just says page not found):
https://www.visa4uk.fco.gov.uk/home/welcomeAnd you need to select Settlement -> Settlement -> Wife for the visa type
2. Your wife must be in the US on the date you submit and pay for the visa, but if you are submitting it for her, it can be done in the US. However, I would recommend that she submits it herself as she will need to print the biometrics confirmation and application form.
She also needs to print and complete VAF4A Appendix 2 by hand.
3. No, you must send EVERYTHING in the same package. Anything sent separately will not be considered. So you just gather up all the boarding passes, letters/cards, emails/calls/messages for both of you and put them in one pile, then add to her application documents in the US. For time spent together, you do not need any evidence of meals out or other tickets/reservations - just the boarding passes from flights.
4. No, just put it in a sensible pile. The business evidence does not need to be indexed separately either. She can just include a contents letter at the beginning listing everything
5. You have to be very careful with your salary and how you pay yourself. Someone just got refused for how they paid themselves as their payslips and dividend voucher amounts and dates did not match the deposit amounts and dates into their bank account. You can only use the last full financial year of income, so it depends when your financial year begins and ends as to what income you can use.
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