>I ran into the same sort of problem when I designed an app to run in 800x600 and the user had a full vertical Office toolbar up...cutting screen pixels to +/- 750 pixels. The screen width truncated to the max the screen could hold. In my case, there wasnt an easy solution.
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My problem is more basic than that though. Something else to try:

Create a form class definition while using 640x480 res.
Set the width value to 1000 (obviously too wide for this res.)
Save the class
Modify the class

The width is now 640!