When creating and slicing a design in Photoshop, the most important thing to remember is to keep it as simple as possible. Don't be sloppy with your slices. An image that is cut up willy-nilly results in unnecessarily clunky and bloated HTML and/or CSS code to make it look right. You want to keep the slices down to as few as possible, and have the dimensions on each slice match and line up where possible.
Moving the code over to your forum can be tricky, and every skin is different. The design dictates which templates you'll be doing the most work on, but the three most heavily modified templates in any skin are generally the header, navbar and footer. Naturally, a lot of tweaks can be done to other templates, but these are the big three when it comes to making large changes to you theme, along with the CSS settings in the Style Manager.
One of the tricker things about coding vBulletin skins is that tags inserted in one template are often closed in another. For instance, a lot of my themes have a div which starts in the header, but is closed in the footer. This can make the coding process somewhat laborious—especially when attempting to debug layout problems among various browsers. That said, vBulletin contains the most robust and user friendly style modification system of any of the other forum solutions I've tried, so it can certainly be a lot worse. There were times I nearly pulled all my hair out when making themes for SMF forums, as the php, html and css code are all thrown together in the same files...and very
large files at that, with hundreds of lines of code.
Speaking of opening and closing tags, pay special attention to the spacer_open and space_close templates and conditionals. Generally speaking, you'll want tags to either bookend these conditionals or be contained completely inside of them. When I first started making themes, I'd often have a starting tag begin after the $spacer_open conditional, and close after the $spacer_close or vice versa. This resulted in the theme breaking horribly on certain pages, and it took a huge amount of trial and error on my part to figure out why. If you have a skin that looks fine on some pages but completely borked on others, these templates along with your tag placement relative to them is one of the first places you'll want to look when debugging.
I don't want to speak too much for other designers, but I believe most do their initial design and testing using Firefox, as this is the most standards-compliant browser. Once you have a theme looking good with it, then begin testing your theme in IE, Opera, etc. Also, make very liberal use of
The W3C Markup Validation Service. A few errors in your markup generally isn't fatal, but you really want to try and get your skin to validate, for browser compatibility reasons as well as making things easier on the search engine spiders. Sadly, a lot of the developers of existing vBulletin modifications pay little attention to this, so even a skin which validates perfectly alone can throw a half-a-million validatoin errors after installing certain plugins/modifications, but I guess that's another topic.
Oh yeah, don't completely rely on the Photoshop generated HTML code when saving your sliced image. This can generally be a good starting point, but don't try to paste this code verbatim into your vBulletin templates. Myself, I prefer to use divs and CSS where possible, and not the crap tables, TRs, TDs and spacer gifs that the Photoshop code presents me with.
Ah...damn...didn't mean to write a book, but I got to typing and couldn't stop myself. If I didn't need to pee so bad, I'd probably still be typing. :cross-eye