Well it looks like Mr Bean & Myself got a bit carried away last night. Nothing better than those 4am sessions....

Ballendo, I guess that screensets are every much a personal thing. I look back at our original post and hope that the later screens have not gone too 'Arty' as this is certainly not our intension. Apart from the brushed panel look not a lot else changed.
The original screen used more than 50 seperate graphics and on my main PC which is 3Ghz + I didn't see any change in screen updates. On some lower spec machines I have I did find them not as responsive although I would say it was acceptable.
I'm afraid the single bitmap background and hotspots makes it so easier to develop. In our case we split the work with myself generating the button graphics and the screen 4 settings. Mr Bean did the hard work doing the background panels with cutouts for the button icons and generated a lot of themes. It worked well, MSN allowed us to chat the design through and the new MSN 8 beta has a superb feature of folder sharing allowing us to syncronise our work effortlessly. (The MSN 8 Beta is a closed one but I do have some spare invites if anyone would like one. It has some good new features).
Our aim for the 1st screen we would release is 1024*768 and would follow the original screen that is bundled with Mach 3. Nothing radical at this stage to rock the boat. Hopefully we are on track to do this.
Unfortunately as you say the method for screen producing now does not really lend itself to tweaks or changes when released.
We are not using RealDraw. The unfinished .set for Mach Blue was abandoned. I don't think I have a copy of it either but I will take a look.
If you post some ideas or layouts that you would like we could always try and adopt a screen for you.
Cheers