This is a great discussion.  I'm always interested in other's
approaches...

--- Ken Wimer said: ---
1) Create a basic 640x480 pic with the correct branding, etc. as vector.
2) scale that down to 640x400
3) add extra highlights, glow and shadows as appropriate
4) save a pic as 24bit png
5) change to indexed color (no dithering), 15 colors if you need to  
add a white or red for text purposes...save the file
6) open the colormap dialogue and swap colors where necessary to make  
it fit to the code...note that your pic starts looking funky really  
quick - save that with another name
7) open the pic without the adjusted colormap from step 5, select  
all, copy, and paste into the one from step 6 - gimp adjust the index  
stuff automagically
8) touch it up per hand as necessary (didn't go this far yet on the  
pics I posted on the wiki)
---

Step 5 is possibly a weakness as well.  While it seems logical to
approach it this way, you are relying 100% on software to do the color
crunch to 16 colors.

You _might_ want to put in two repeating steps here and see if your
quality increases:

5) Crunch 24 bit PNG to an indexed color image of varying size.  If your
image contains careful gradients and antialiasing colors (experience
will tell), try shifting to indexed colors in phases.  For example, you
might try going to a 256 indexed color image, flip back to 24 and remove
the anomalies.  Then crunch to a 128 color, flip back to 24 bit and
again touch up.  Work your way down to 16 colors.  It should almost
always yield better results because you are using a human eye to firmly
seat the image.
5.1) Once you get your image down to a 16 color palette, do the color
mapping dialogue and shift your indexes so that they match up with the
proper pre-defined usplash indexes.
( https://wiki.ubuntu.com/USplashCustomizationHowto?highlight=%28usplash
%29 for more information.)
5.2) Take a step back to your original 16 color png, and re-adjust it
via the mode dialog using the new palette.

That theoretically SHOULD leave you with the best image possible.  That
said, you might hit the little compile bug that I have been getting.

We should probably wikifize this once there is enough information
gathered.

--- Étienne Bersac said: ---
1. Create a 640x480 picture with Gimp
2. Export it to PNG. Convert it to 16 colors with Gimp (don't know
how to order colors in the palette with the Gimp). Be careful
about flat surface. manual retouch. etc.
3. Resize it to 640x400 with convert (i wish it keep the palette,
but not sure)
4. pngtobogl it
5. build, link it, etc.
---

Again, the step 3 relies on software to effectively try to 'guess'
the best antialiasing color set.  It might be more effective to work
in a non square pixel environment (via the DPI settings) and visually
ensure that the pixels are anti-aliasing efficiently.




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