Ah, sorry - you posted on Christmas Day and not many of us were checking the forum at that time

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- Are the barcode separators from VFS Global necessary to include in our application? Or is just putting all the documents in order ok?
Honestly, we don't know for sure. Some people have used them, some people haven't, and so far we don't know if it makes a difference.
- Do the 2 passport photos need to be on A4 paper as well? or is it ok if they are small?
Only 1 passport photo is needed and it should be an actual US or UK sized passport photo.
However, the photo is not used for anything, and is usually sent right back to you anyway, so it may not matter. I don't actually think you need to send any passport photos at all, because they use your biometrics photo for the visa, but the supporting documents guidance still seems to mention it.
- If I had my first name changed, should I include in my application the court orders showing my name change and my birth certificate with my old name?
I'm not sure if you need to, but it's probably a good idea to include it anyway.
- For the boarding passes, can we just put all the boarding passes on a word document just like with the WhatsApp/messenger/facetime photos?
No, they should be the actual boarding passes that you presented to the airline staff when you boarded the plane, or the actual print-outs of your e-tickets.
- For photos showing proof we met in person, is it ok that I put 4 pictures in a word document?
Ideally should be on actual photo paper. No more than 2 photos maximum, only you and your sponsor in the picture. We usually say to send one recent photo/one from the wedding, and one from earlier in the relationship.
- Since I was in the military, should I provide a copy of my military orders showing when I was stationed in the UK?
I don't think you need to.
- For the VAF4A Appendix 2, I fit section 3A and none of the others 3b-3f apply to me, can I leave the fields blank? Also what kind of things did you put in the box at the end "Is there any other information you wish to be considered as part of your application?"
You must leave all the other sections of Part 3 blank, otherwise they may think you are meeting the requirements using all the categories!
So, you only fill out 3A and then move directly to Part 5. But most people leave Part 5 blank, or use it to finish other questions that they didn't have room for.
So, you're basically just filling out:
Part 1
Part 2
Part 3A
and leaving the rest of the form blank.