I use an eBook compiler to convert WebHelp to an executable file. You might investigate eBook compilers for that bit. However, I'm not sure how that would help you since a compiler will do little more than to take a swarm of WebHelp files and store them in a wrapper to create a single file. Generally you will end up with something that although it exists as a single file, is larger than what is inside.
Are you SURE it's too big for CD? CD will hold 650 megs (700 if you buy the extended types).
On the screen size issue WebHelp itself should adapt fine. Probably it's the images you are concerned with. And the general rule of thumb is to capture images at a reasonable size to begin with. Never EVER just insert a big ole image into RoboHelp and grab the sizing handle to make it smaller. It will still consume a larger amount of space and the quality will suffer badly. So the best approach is to copy the image at a reasonable size to begin with. Something that may fit nicely in the Topic Pane area as it is presented in the space provided by the lowest common denominator. In your case I believe you said that many are still at 800x600.
Your 10 point text will still be 10 points at a smaller resolution. It will just look a bit different.
Hopefully this helps... Rick
Thank you so much, Rick! Doh! I don't know what I was thinking about the CD! Yes, it definitely will work. Regarding the images, when you say "copy it at a reasonable size to begin with" I assume you mean resize it in the capture tool before saving it (I use SnagIt, and it has a resize feature), right?
Anyway, thanks again for your help!