Randy, thanks for the tip... )
DavidK, thanks for the suggestion to check out Alien Technology I just now downloaded it. (Would have gotten back here sooner, but yesterday was my fiancee's birthday... you know how that goes

)
Thanks also for the comment about the 3-pixel border... that was one of the things making me wonder if my install of Skin Studio was corrupted, glad to know it's not just me.
Your suggestion about looking at the converted UIS1 skins as new skins has me thinking now though... How many subskins is too many?

I'm doing a texture-emphasized monochrome theme, and I have 12 color variations. I had originally planned to just do one version and employ the colorizing features of WB, but this feature gave some surprisingly (to me) inconsistent results with the texture, which is gradient-based.
Anyway, if I now add UIS1 subskins, that would bring me to 24 subskins in one file! I have also been experimenting with a version with compact start-menu and thinner bars for a minimalistic feel using the same features. So now I'm wondering if I need to think about repackaging this thing into a few smaller uploads... Any suggestions?
P.S. joetheblow, I apologize for somewhat hijacking your thread, but I think this is related to your original question. I hope you don't mind.
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