Hey Don, I think your problem is with the pixels or lack of pixels. If you want super sharp edges you'll need to be accurate right down to the pixel and you'll need to do this on your final size. Once you've reduced the image the pixels from your large size will end up being split between pixels on your reduction. The chances of a 2 pixel line ending up in exactly 1 pixel width are pretty small. You'll have the same problem with vectors, even on the reduced size. A vectored line is more precise and more likely to split your line between two pixels. Be aware of the pixels and how much room you have to work within them at your reduced size. And do try the numbers on your final reduced size file. They may work out spatially within the pixels you need to work with but there's a chance you don't have enough pixels for the proportions and sizes you need.
Or at least that's if I understand the problem correctly
