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Thanks again guys. I have changed the block padding to 5 px all around and updated the zip files. Hopefully that will help people out a bit
Javelin is right, if a block from a module is set to 250 pixels and the column it is in is only set to 200 pixels, it will cause wrapping problems. So to fix that either the theme needs to be changed to have bigger columns to match your needs, done here:
in style.css:
Search and replace "12em" (14em for fixed theme) with whatever you need, IE "14em" for bigger left and right columns, etc.
Or you can edit your module template files to not use tables or items bigger than (12em wide. 1 em = 16 pixels at a user's default font size setting) Or replace 12em with 100px to make sure the columns stay the exact width you want and not be relative to the content, that could cause some of the column wrap problems. If you do edit your module's templates, email me the replacement template and put it in the theme to replace those templates for others. I've already done this for a couple modules - mainly to strip out tables and be W3C HTML compliant.
Just remember, these themes are designed to be wireframes to help future theme developers have a common starting point to develop a theme that is CSS based and W3C compliant - These themes are not designed to be a drop-in-place-and-go theme. They may very well need to be tweaked to meet your site's needs. Every site is a little different and may require different block margins, column widths, etc.