size should be aspect ratio of either
4:3 for normal, and 16:9 for hi definition
for 4:3 it should be 640x360 or higher, ipod uses 320x240, I don't know for hi-def
You can convert to either format (Divx 5 or 6) depending on your needs, but Divx 6 has better quality per bit rate, and is obviously newer.
AAC audio is supposedly better than MP3, but AAC audio isn't supported in .avi
I don't think you need the chapters.txt file
Oh and remember that the TV does an overscan for the subtitles so they appear to be cut off if you put them too low.
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