This is an old question, but I wanted to write a proof that $A_5$ is simple via symmetries of the icosahedron, using as little group theory as possible. I don't think that it can lead to a proof of the unsolvavilityunsolvability of the quintic without the usual group theory (permutations, normal subgroups, quotients, solvable groups), and, of course, field theory.
Regarding the question Q2, there is an interesting (though not quite elementary) application: The fact that the icosahedron group $G$ is simple is the firsta step in the construction of Poincaré's homology sphere, a 3-manifold $M$ that has the same homology of the sphere $S^3$, but is not homeomorphic to $S^3$, because its fundamental group is nontrivial. It is said that thisA construction of this kind allowed Poincaré to reject a preliminarpreliminary wrong version of his famous conjecture, which was originally stated in terms of homology (a 3-manifold with the homology of the sphere is homeomorphic to a sphere, as happens in dimension 2).
The homology group $H_1(M)$ is obtained by abelianization of the fundamental group $\Pi_1(M)=2G$, so we must prove that the commutator subgroup $[2G,2G]$ equals $2G$. Observe that $\pi([2G,2G])=[G,G]=G$, where the first equality holds because $\pi$ maps $2G$ onto $G$, and the second one holds because $G$ is nonabelian and simple, so the nontrivial normal subgroup $[G,G]$ must be equal to the whole group. So $\pi$ restricts to a surjective morphism $[2G,2G]\to G$ and there are two possiblitiespossibilities:
Since the angle-of-rotation distance in $SO(\mathbb R^3)$ is just the double of the geodesic distance in $S^3$ (which is the angle of vectors), to verify what I claim we just have to prove that $2G$ is $\frac{2\pi}{12}$-dense in $S^3$. This, if true, can be checked numerically with error of less than 1 degree. But it would be more interesting to have a picture of the Voronoi-cell decomposition of $S^3$ with respect to the discrete set $2G$. I wonder if this leads to the other usual presentation of the Poincaré sphere (as a quotient of the dodecahedron, identifying opositeopposite faces by a $\frac{2\pi}{10}$ right-handed twist).