(Really) large button images - possible?

Hi all.

I've got a couple of toolbars with mostly 64x64 pixel icons taken from individual image files (mostly .PNG). There are a few I can't fix with my limited artistic and which are therefore using the default large Icon size of 32x32 (taken from the .ICO or .EXE files). I've unticked the "Scale toolbar button images when larger than standard size" option in the Toolbars/Appearances section of the config, so these images are correctly displayed at 64x64.

I now want to create a new toolbar using larger images, probably about 250 wide by 100 tall. However, in the newly-created toolbar, the icons are appearing half that size, 125x50. I know it's possible to create larger buttons - I've just used a 256x256 image on an existing button and the bar displayed it at a larger size, but scaled down to about half the source image's size. I'm guessing that this is due to a limitation in the maximum size that Opus will display on a button - am I right?

Following on from that question: if the maximum size of these buttons is set somewhere in the Opus settings, will changing it in order to accommodate my new 250x100 buttons make a mess of the existing toolbars using different sized icons?

And one final question: Ideally, I'd like the new toolbars to have no gap between buttons. I see that the Toolbars/Appearance allows you to set the button spacing, but only as low as one pixel, and only on a global basis. I'm guessing that it's not possible to go to zero, or to set them up per bar - is this correct?

The new 250x100 buttons will be replacements for existing buttons. I'd really like to take the existing 64x64 buttons and just replace the images, rather than creating entirely new buttons in either Opus or some other toolbar program.

Thanks in advance.

I don't think there is a way to have icons that large on the toolbars (without scaling), nor to reduce the spacing to completely zero.

When you convert the ICO files to PNG files, does that solve the problem?

They are all already .PNG files, so no luck there. I assume that Opus is hard-coded to only display images up to 128x128, though I can't work out if there's logic or pot luck behind whether your icon gets scaled to 128 pixels on its longest side, or 50% size.

I've just spent a few minutes aligning my toolbars very precisely (to the pixel - a lot of time spent staring very closely at the screen) only to have the old resizing toolbars bug crop up again (I've posted about it before). Also very frustrating. I'll have to try and trick the bars into staying put before I align them all over again.