No. You cannot legally download a ROM image even if you own the game. While US copyright law does permit a backup of most media (providing you make the backup yourself), the verdict of the Atari vs. JS&A lawsuit would indicate that video game cartridges are non-volatile and are thus not permitted to be duplicated, even for personal use. Also, if the game has any form of copyright protection on it, copying it would be a violation of the DMCA (Digital Millennium Copyright Act).
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Technically, yes it is legal. What people don't seem to realize is that the only thing that doesn't allow it is the xbox terms. The U.S. law states that you are allowed to burn it if you own the original copy. If you don't own the original copy, there is no law that says it is illegal or legal. Therefore, it is safe as far as legal issues go. The only consequence you may face is getting banned on xbox live which only happens if you burned a game incorrectly which almost never happens. I have been burning xbox games for years and have never run into any trouble.
No, not usually. Mostly, you need to own the core game. There are some episodes of games that you can play without owning the original, but they are separate games, not add-ons.
Downloading BIOS files from the internet for video games is illegal.The only legal way to download BIOS files is to dump it from your own video game console.
No, it is specifically stated in the game "This is not able to play". They do not have effects of their own and retain their original lores.
You can not physically make your own YuGiOh cards that are legal to use in any sort of game. However, you can make your own gag cards for comical reasons. Instructables has a tutorial on how to make them using an image search.