Thought I better start this as a seperate thread.
You can use line fill actions instead of AS lines to resize your character and it's line work will look perfect at any size.
Benefits: You get perfect linework that will export to swf without using the Var linewidth checkbox. Also line fills can be shape adjusted for areas like the mouth etc.
1. In this picture the first character is the original character with linework as I want it to look when enlarged. The second character (small) is the character as I want it to look as a thumbnail with shape fills adjusted. The third character is an enlargement of the small character after the line fills have been adjusted.

Steps:
1. Create a character with line fills.
2.Copy and Shrink your orig character down to a thumbnail size and then begin to resize and adjust the line fills while it is small. Work small. You get a better idea of what it's going to look like at a thumbnail size.
3. Copy and Resize the character to it's orginal size.
4. Using the re-sized version as a reference, scale up and adjust the line fills on your original character to match as actions.
Your character will scale and export to swf perfectly without any interference from AS auto adjustments.
http://www.wienertoonz.com/linefillactions2.swf
Cheers
D.K