Simon,This is a very thorough and inmirfatove post! Coming from a background as a project manager in an interactive agency, I can attest to all the time and steps involved into proper web development. It’s a lot more than people think and you hit it right on the nose.Now that I’m a part of ProtoShare, I would have to (slightly) disagree with all the user testing being done at the end of the site build. (and tools like it) allows you to build your block wireframes (grey-box) in an application that makes them interactive. So you are not only showing your clients the widths and margins, but they can visually experience how the pages are connected to each other. From there, you can evolve the block wireframes into a more visual prototype. At this stage you can conduct initial user testing to make sure the site is intuitive and uncover any areas that aren’t prior to your coding.I am not saying this has to completely eliminate the user testing at the end, but it can uncover usability issues before you have to rework any pages in HTML or CSS therefore saving time.We are open to feedback if you have a chance to try the application. I think it would fit in nicely with your process.Cheers,Andrea@ProtoShare