At this point, I have tried them all. I hand rolled my solutions; used early versions of WSPBuilder; struggled with the interface for VSeWSS 1.0, 1.1 CTP, and 1.1 final; and even tried a few offbeat solutions.
Until this summer, every method had serious problems that made packaging and deployment problematic. Revisiting my posts, I see that I never mentioned this before, but I owe props to my colleague Ted Calhoon who turned my on to the WSPBuilder Extensions. I switched over, and I never looked back.
They are a bit counterintuitive, and the commands to flush out the folder structure are well buried, but once you get the hang of them, they are the best around - at least until someone comes up with something better.
In future, I'll do a walkthrough.