If you want to chuck us a list of the customisations that are being
mangled by sysprep I can let you know what we've done to address them,
we use commandlines.txt to sort some of the issues encountered in
respect to issues that need to be resolved prior to the system's first
full startup, and use Altiris to deploy any other config changes, but
anything we're doing with Altiris you'll also be able to do in the
GUIRunOnce section of the sysprep.inf presumably, we don't use this as
Altiris is much nicer, but from memory it doesn't require a login to
kickstart so should do the trick.

Out of curiousity why are you using Sysprep? If it is purely for machine
name/SID changing then you're using a bazooka where a hammer would
suffice, sysprep is highly intrusive and mangles things quite nicely. It
is the ultimate solution for hardware independant imaging with XP, and
if that's what you're using it for then well worth the added effort, but
if you're doing it purely to change SIDs/PCNames and still use seperate
images for different hardware as many places do you'd be much better off
just imaging and using a tool like Newsid to make the mods you need, and
all your customisations will stay intact perfectly.

Alternatively if you got some money floating around you could look at
virtualising your desktops with VMWare and just picking up a whole heap
of cheap thin clients. We're only virtualising our servers at this
point, but the virtualised desktop solution looks magic from a
presentation we recently went to, probly trial it further down the track
when we've recovered from the outlay for getting the gear for server
virtualisation, but if it's half of what it promises to be it'd
eliminate all the probs we're seeing with different hardware and a whole
heap of other sh.t all in one blow, but potentially bandwidth would
become a much bigger issue, but that's all another story....