Thanks for your help... I did do major editing of that template, and there really isn't all that much that is left of the original, most of which is in the menu area. *grin*
It is a strange problem, I wrote the skin for one site of mine, and it worked great, I tested it in every browser I could get my hands on and it displays correctly every time. I did notice the extra spacing you were talking about when I first got the template, but after a lot of editing it disappeared. Once I got done with it, I put it on another portal (it was a host-level skin), and noticed this problem with the first/last items in the menus. I looked back at the other portal, and it was still displaying correctly, in the same browser but in a different tab. Right now I have it on three portals, and two of them are acting up while the third appears to work fine.
The rounded-glossy corners in this menu are nothing fancy, they are basically just a background image showing a rounded edge inserted into a table cell. I played around with the width quite a bit, and it appears to be correct. The problem appears to be the background image of the menu, where in the first and last items they are shifted to the left about 50 pixels. When I remove the "norepeat" option of the menu CSS, it does tile out to the full 150 pixels, so I know the width is okay. In addition, any menus titles that are too long extend past the background image, right out to the full 150 pixels.
Then, I narrowed the problem down to the first, last and firstlast items of the CSS menu by removing those sections from the CSS. When those sections were removed, the menu displays properly, the only thing different is that the top and bottom items don't have the rounded corners (which makes sense, since that was what I removed).
I tried many different tests with the suggestions you gave with no success. But, I think that was mostly because the suggestions you gave were in regards to the menu (table) width, which is actually working correctly. I did change the overall width from 160 a few times, but that had no effect either. The .txt class (and a couple of others) is being applied to those menu items, but since it is also being applied to the rest of the menu items (that display correctly) I don't think that is the culprit either.
I didn't get too far with the Firefox plug-ins because it displays correctly in that browser, but it does show me that the menus are being rendered in the browser with X/Y coordinates, so I'm wondering if there is a bug in the software that is applying the wrong offset. I'm running 5.1.2 right now, I'll try upgrading to the newest release and see what happens.