Thanks for the info, that's missing in help file until now...
Anyway, I think it's strange that you have to enter a height of "25" in buttonbar config and this value is then stored as a "30" inside wincmd.ini to make a 24*24 icon fit. The same adjustment, 24 => 25, has to be done when "Little Icons" is activated, so there is no difference here besides the cut icon looks a little better maybe.
This option works just like in TC <7 (imho ugly) but the icons are really 24². You can't complain about that
I don't doubt that they are NOT 24*24 but there is a difference between classic and XP styles, I was wrong above. TC buttonbar height is optimized for XP styles, so if you enter 24 you get an exact fit. It's ok like that, but it should be mentioned in the help file that users have to take care about that themselves when they switch to classic mode, otherwise they get a squeezed view.
By the way, why are the descriptions of the two size fields that bad?
The first one should be called BUTTONHEIGHT instead of "size".
The second one should be called ICONSIZE, right now it doesn't have any name which is very confusing.
Also the term "Little Icons" is far from being perfect, it should be changed to something more meaningful like "match iconsize".
Icfu