Jade!
I took your lead and now have www.royalindustriesinc.com "source ordered" per our discussion above. Everything works pretty well and seems stable. When you check the page without CSS you get the page content first, then side boxes then the drop menu ( and all my endless categories ;P ).
This didn't take long at all. But like you said, some tweaking involved in getting the header to have enough space. I actually used 'margin-top' to push the centercolumn down.
Two things I have noticed. Since I am not using a stretch logo, and have my header a static height, when you zoom I get a bit of space below the menu. Acceptable though.
However! Now that the header is loaded after page content, my logo doesn't get loaded and displayed quickly! This is loaded with the CSS if I remember correctly. If I do an "on load" command on the body element will it get cashed and displayed with the page? I have done this before, but not using CSS to specify images... hmmmm.
As far as making this a core to applezen... I think I must agree with you. There is a fair bit of mod work here and I think you need to be comfortable with playing with the CSS and not afraid to change the php. But, you could certainly have an FAQ with the mod that answered your common questions, and maybe also one for going source ordered.
Anyway, I am REALLY happy to get page content first! Excited to see what happens with my page ranks now.