Sweet... I'm glad screen calibration is coming along. Actually after looking at the screenshots closer, the images actually look pretty good and detailed upscaled to the 1920x1080 screenshots even though the original source was only 640x480. So maybe having a lower res pic will do and not require skinners to have full 1920x1080 image if the size limit can't be overcome.
Answer to questions:
The font is barely readable at 1080i and is rather too small for my taste. Plus I'm viewing it on a 65" screen. When I split my screen in 2 which is aprox a 30 something " screen, the text is not legibale at all. I believe a means to scale the font would be best.
The systems info/settings screen are nearly identical to the file browser. It is a bit more clear in my opinion but def need to be scaled as well. Also the white lines surrounding the volume bar graph as well as the pop up confirmation screen flickers just like the white lines in the file browser. I'm guessing that the white line is one pixel width and hense getting the whole flicker effect from the interlace aspect of 1080i
I also just tried the blue asura skin to see if the intro video would slow down like the ones i watched from the file browser. The videos played fine but the menu navigation had extremely slowed down. In particular, the smooth transition in between items in the menu
As far as suggestions goes, each HDTV set is going to be different. Lots of users are gonna use 1080i and the rest are gonna be die hard 720p. And as you said, the overscan is different for each of these modes. So screen calibration is a def plus and pretty much a necessity for hdtv/xbox IMHO...
Also the fonts look nice and sharp and somewhat legible at least on my set but again, this might be due to the size of the screen as well. Even if the fonts were scaled just a bit larger, it would still not fit everyones needs, although would help tremendously on mine. So giving the user the ability to scale all the system/file browser, and possibly even the skin-menu/info fonts might be a good option to have in the systems menu.
I'm defenitely loving how the dash looks so sharp right now at 1080i! Great work once again on the dash!