Hi Randy
Well, you were right (of course) :-)
My Elecrow 7" 1024*600 touch screen display was the problem ... but there was a solution out there.
I decided to try and build a Picochess 4.2.2 image myself by following the guide on Johan Sjobloms Github page. I used Raspberry Pi Imager to flash the latest Trixie-based Raspberry Pi OS 64-bit to a 64GB MicroSD-card. At first nothing seemed to work, as the boot process quickly spilled over into a display error message: "No Signal".
I used Grok to guide me through every time I ran into an issue. It was really helpfull and identified my display in connection with KMS as the issue. I therefore started by muting all KMS in config.txt. This removed the "No Signal" error, and my Pi booted to the prompt. Still, I was only able to get into desktop mode by typing "startx" at the prompt. Grok correctly nailed down that my screen was not able to run full KMS. The solution was surprisingly simple: Just switch to fake KMS. This means I only needed to edit one single letter in the KMS command in config.txt by changing from "dtoverlay=vc4-kms-v3d" to "dtoverlay=vc4-fkms-v3d".
Also I added a few lines at the botton of config.txt to ensure correct display output:
hdmi_force_hotplug=1
hdmi_group=2
hdmi_mode=87
hdmi_cvt=1024 600 60 6 0 0 0
Now my Pi4 finally booted automatically into desktop mode ... but picochess GUI did not start (though picochess was running in the background and accessible via the web server). Grok then helped me to activate kiosk mode. BAM! Now my Pi automatically booted into first desktop mode and then into picochess GUI!
Still, I had no sound.
Grok also helped me here. I just had to add a few more lines in config.txt:
# Force HDMI audio even if EDID doesn't report it
hdmi_force_edid_audio=1
# Ensure HDMI is treated as having audio (common fix for custom modes)
hdmi_drive=2 # This enables HDMI with sound (DVI mode=1 disables audio)
Reboot and ... everything finally works!
Hopefully this information will be helpfull to other picochess fans with custom HDMI displays.
Regards
Torben