yeah, i design for 800x600 but use 1024x768 as the overall guide size. In other words even if peoples screen is set at 1024x768, there is nothing to say their browser is that large. With all these bars, plug-ins and of course scaled browsers, you may be getting loaded in something a lot smaller.
Also if you designing on a huge cinema screen, test it on something smaller. or use some of the plug-ins for it (firefox has a web developer plug in)
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