Font size has been a royal pain in the butt. Are you using Internet Explorer 5 by chance?
While you’re working on fonts, any chance the index page can get an option for a sans-serif font like Arial?
The behavior of site_search_extended mode is a little weird. The menu can have one setting, but if the text box already contains a title: or do: qualifier, it is not handled correctly. Also, the asterisk in the text input box gets in the way when entering a search query.
For what it’s worth, webkit.org has some excellent new HTML/JavaScript diagnostic tools for Windows and Mac. There is a new web page inspector with multiple viewing modes, a new error console, and a new JavaScript debugger app called Drosera which allows breakpoints, single-stepping and variable inspection. The WebKit browser is the open-source counterpart to Apple’s Safari web browser.