I realize this post is not contributing much; but every once in a while you're just so excited by something you want to share.
The latest kitchen is greatness synthesized! You could bottle it and sell it at this point. I bought my phone on December 27th 2006, and today, it is what I finally wanted it to be. It really took off for me when I figured out how to grab the OEM's from the FTP site and add them into the kitchen.
This is purely my opinion, but I would recommend to anyone thinking of flashing a new ROM, focus on cooking your own via the new kitchen. just download it and start reading BigJ's instructions.
As far reconciling BigJ's instructions with the actual ROM building process, I can tell u what I did when I got the FAT16 error message...
1) Cancel out of the Encoder / .bat process.
2) copy ur 'nk.nba' file from the 'temp' folder to the 'tools' folder
3) run 'HTC64_Extended_ROM_Tool.exe' from the 'tools' folder manually
4) On the 'Extended ROM file' field, lop off the directory structure and simply go with 'nk.nbf' (just like the picture shows in BigJ's instructions
5) On the 'Fat16 file' field, lop off the directory structure and simply go with 'nk.nba'
6) click 'Encode'
7) move the resulting 'nk.nbf' file from the 'temp' folder to the 'upgrade' folder
copy the 'APACUpgradeUt_noID.exe' file from the 'NoID flash utils' folder to the 'upgrade' folder and run it.
9) follow the instructions