CatBus said:

I find the theatrical subs to be harder to read than font-generated subs. But readability and pleasing appearance are not the point. Chyron wants theatrically accurate subs, which I don't think is unreasonable for a theatrical reconstruction. The only way to achieve theatrical accuracy is PGS or burnt-in, and PGS doesn't work everywhere. You can't work around this by changing the format of a text file.

Ehh... I'm not so intransigent as to only accept one possible answer and be a jerk otherwise. And after reading the Project Threepio readme, it seems it would be possible (perhaps even fairly simple) to mux the "matching" subtitles into the film. If this were a DVD, it would just be a matter of encoding the film to a file while including said muxed subtitles; but this project involves PGS files, which from what I'm reading requires an AVISynth plugin to be able to properly use, and even then people still recommend using AVISynth to burn them in, which defeats the purpose of the whole idea.

I know Handbrake has a nightly build that supposedly supports PGS, but I tried that (with a different film on bluray ) and it doesn't really work.

I've been ripping my parents' movie library to put on their NAS, and my inability to work with Bluray subtitles led me to start using Subtitle Edit, which OCRs them and writes them to SRT.

But I agree that DVD subtitles do look jagged-y, and not as good as the theatrical burned-in subs for SW and ROTJ.