Yeah, the "phantom shadow" is the reason. My workaround was to add a dropshadow to the font itself. I know it's not optimal because the shadow is visibly thinner but this way the HUD has Übercharge percentage at the ammunition's place (which I had wanted for a while) as well as proper Vaccinator support.

Version 3.31 (forgot this in 3.3)
* Added killstreak icon to TargetID and TargetID_oldschool.

Modified files: targetid.res, targetid_oldschool.res

Moved MapName out of LocalPlayerStatsPanel and repositioned it accordingly. Removed GameType because it doesn't seem to work anymore. Credit to rays who actually discovered the fix!
http://www.diffchecker.com/4gvwge2u

Version 3.3
* Added Eureka effect teleport menu.
* Fixed "[unknown]" in the scoreboard.
* Moved last damage done above the ammunition.
* Moved Übercharge percentage and number of individual charges (Vaccinator) to the ammunition's place.

Modified files: clientscheme.res, hudlayout.res, hudammoweapons.res, huddamageaccount.res, huditemeffectmeter_powerupbottle.res, hudmediccharge.res, scoreboard.res
Added files in resource/ui/build_menu and resource/ui/build_menu/pipboy: base_active_teleport_target.res, base_unavailable_teleport_target.res, hudmenueurekaeffect.res

http://www.file-upload.net/download-8397686/main_menu_characters_removed.vpk.html

I just remembered that I had this lying around. Put this file in your custom folder to remove the main menu characters. If I recall correctly, it's more up-to-date than the download provided in the guide. You can rename the file however you want by the way.

Also, the list in step 5 is incomplete. These are the file names you need:

background01.vtf
background01_widescreen.vtf
background02.vtf
background02_widescreen.vtf
background_2fort.vtf
background_2fort_widescreen.vtf
background_gravelpit.vtf
background_gravelpit_widescreen.vtf
background_mvm.vtf
background_mvm_widescreen.vtf
background_upward.vtf
background_upward_widescreen.vtf
background_xmas2011.vtf
background_xmas2011_widescreen.vtf
title_blue.vtf
title_blue_widescreen.vtf
title_fullmoon.vtf
title_fullmoon_widescreen.vtf
title_red.vtf
title_red_widescreen.vtf
title_team.vtf
title_team_halloween.vtf
title_team_halloween2011.vtf
title_team_halloween2011_widescreen.vtf
title_team_halloween2012.vtf
title_team_halloween2012_widescreen.vtf
title_team_halloween2013.vtf
title_team_halloween2013_widescreen.vtf
title_team_halloween_widescreen.vtf
title_team_widescreen.vtf
title_war.vtf
title_war_widescreen.vtf

http://steamcommunity.com/sharedfiles/filedetails/?id=166159968

This doesn't quite work because while trying to display the log, HTML MOTD gets diabled again and you'll see the text MOTD instead of the log.

alias +log "cl_disablehtmlmotd 0;say !log"
alias -log "cl_disablehtmlmotd 1"
bind l "+log"

Works if you hold the key for like a second.

http://teamfortress.tv/thread/8335/custom-caption-tutorial

http://etf2l.org/forum/customise/topic-16829

Having TeamFortressTV and VanillaTV cast the same game is counterproductive in my opinion.

The outline of the open cross doesn't work properly, I don't know why and it bugs me more than it should. Resolution is 1680x1050, the crosshairs are centered, crosshairsoutline18/24/32.
Screenshot: http://abload.de/image.php?img=opencrosscdcdx.jpg

Also, the HUD element when being autobalanced seems to be from the default HUD. Not saying you have to edit it but it surprised me a bit because of your emphasis on details.

The killstreak number seems a bit isolated and I think adding the killstreak symbol could really help. I'd love it if you designed it like this as well:

http://cloud-3.steampowered.com/ugc/486696665271317445/5C2D2C98DAC00C593E92E8080F9D370D47681896/

The file if you want to take a look at it: http://www.file-upload.net/download-8854364/huditemeffectmeter_killstreak.res.html

Go into resource/ui/hudplayerhealth.res, find "PlayerStatusHealthImageBG" and edit the image value to "../hud/health_bg".

It has to look like this in your case: http://abload.de/image.php?img=clipboard02x4ki9.jpg
If it doesn't work you're doing something else wrong.

Vaccinator stuff seems a bit broken:

http://cloud-3.steampowered.com/ugc/486696207831288082/2935A8CB1F19380C361087D35666AFD62BB80F7A/