Updated for php4/5 now. Was an easy change. New readme.txt in initial topic post.
Btw, only place(s) that you would need to change the value from 40 chars to different is in the call to html->hop_to(40) in either showflat.inc.php or postlist.inc.php or both.
No need to change the function itself, as it takes the value you send it. If you don't send it anything. ie: html->hop_to(), the routine will default to 40.
One thing to also note. If your .popup_menu_content class has a width restriction on it, you'll have to consider what to do. My classes have width:auto; on them. :2c:
And to giz-unit. To change the class for the categories is easy peasy too.
$hopCat = "<tr><td class=\"popup_menu_content\"><a href=\"{$config['BASE_URL']}/ubbthreads.php{$var_start}ubb{$var_eq}cfrm{$var_sep}c{$var_eq}$cat\">$cat_title</a></td></tr>";
change that "popup_menu_content" to oh say... "popup_menu_header" and the categories will be classed appropriately. you can of course use tdheader too.. whatever fluffs your flannel

keep in mind that there are two instances of "popup_menu_content". the 1st one is for the category loop and the 2nd one is for the forum/subforum loop. you'd be changing the 1st one, most likely.
Thanks for the input(s) peeps..
Enjoy!