Hey DJ, if you're still interested I think we may still be able to do something. SUP files with PGS contents definitely work on Blu Ray because I've made test discs already. However, they might not work with all authoring software--that might be the problem. I'm just using the free stuff: tsmuxer and multiavchd, and I haven't done any menu interactions at all, but I can definitely say it works with Blu Ray, using the remote's "Subtitle" button to switch around.

I also have "regular" subs that are traditional mostly-below-the-frame Arial subs (non-English subs have to be like this). Also if you don't like the fonts/placement I've used, you can plug in different values and generate your own SUP files. The workflow is pretty simple, and I designed it to be a framework anyone can use. Basically you plug in an SRT file and out pops a nicely rendered 720p subtitle.

My project really has its own priorities and they might not mesh 100% with yours. I'm not terribly intersted in fidelity to existing home video subs for example, and I make changes whenever it met some other goal, some as having the text onscreen slightly longer, etc. Let me know if you're interested in any part of this, I'm flexible and would not be offended if you wanted my process but not my files, etc.

I still want those screencaps tho ;) But I'll wait.