I double checked the Starfox watch roms, didn't find any errors in them. I didn't look into the program rom decoding yet. The SM530 melody rom decoding also appears to be different from SM511. I tried the SM511 raw2good conversion and playing it in a loop, can't hear any of the jingles. That is, assuming the melody controller is actually the same one.
I'll put together a possible ROM for you to check out.
That's a bummer about the melody ROM; the array looks pretty much identical to the SM511's. Maybe it's something simple like the bit order is reversed.
