(1) Note that on page 19 it says to leave the default setting of 163 x 245. If you don't than XML document will be clobbered with a different, unsupported XML one, which is not compatible with the theme. At this time there is only one mode for STD and WALL, which is driven by the theme template. Why, because each theme template was created such that the LIST and or THUMBS fits within the area expected on the template.
If this wasn't done then the thumbs, like your size, would clobber the template design.
However, in your case you appear to NOT be using a folder template when on a folder and are likely hiding the thumbs when viewing a movie. I will look into supporting, for WALL and STD modes, a few different configurations, especially now that users can use their own (non-theme) templates using FULL JPG ONLY option. I will look to squeeze this into one of the pre-release 2.0.3 stages starting in a few days. This enhancement will not be offered in the first phase of this release.
(2) You are referring to the "Pop-Up" feature from version 1.02 of the OSD MovieSheets+ application. Release 2 was a complete re-write and as indicated on my website and documentation, it focused entirely on the new theme feature. It also stated that features from 1.0.2 would be introduced back into 2.0.X in subsequent releases leading up to release 2.1.0. As many of the subscribers will attest to, I tried to introduce the Pop-Up feature back in release 2.0.2, but unfortunately it was causing a crash situation of the OSD. This crash issue has been documented by other developers when trying to read pre-defined variables associated with the browse XML's. However, I am happy to report that I AM introducing it in pre-release 2.0.3, phase 1. I have found a method to limit my XML variable reading\changes to one value. This is not 100% bullet proof though but appears to be fairly stable in my use of the WD. As such the Pop-Up feature will be configurable (turn on\off at your choice). I look forward to the feedback during the 2.0.3 pre-release stage.
(3) There are two templates for every sheet. One is used to create the JPG (in sheet mode would render a JPG sheet that is 1280x 470), and the other is to render the PNG transparent piece (in sheet mode would render a PNG sheet that is 1280 x 250). So you need to change both the input/output to PNG and choose the transparent template. Sounds like you didn't switch to choose the PNG template, as I have never seen a PNG that large unless you were generating a much larger sheet, hence my suspicion you are still using the 1280 x 450 template for JPG.
Check your resolution\size of the PNG sheet in question and confirm it is 1280 x 250. I have created over 10,000 sheets, using STD, WALL, SHEET mode, with different templates (including the Winter Soltice) and only have found a few that would generate at 800K and not compress beneath 512K. For those, I simply chose a different background picture and that resolved the issue.
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