1. The software won't let me install more than 31 (with 8 system buttons) no matter what their size.

2) I've had quite a few "Subscript Out Of Range" errors.

3) Yup, there certainly is a minimum size. I don't know what it is exactly, but I found 8x11 worked OK. I created a black dot for unused main menu buttons (solid white also would not work, probably because it was masking out the entire button) and hid them in other buttons.

7) Yes, uploads have a long way to go...