1. Do you create a separate dwgs for each dim/viewport scale that are equal?
No, I have a variety of scales ranging from 20 to 200 in the same drawing and keep my psltscale and ltscale set to 1 for each viewport. I am trying to enforce that any dimensions (very few in our drawings) and most text be in paperspace only so only one dimstyle is needed. The exception is for plats where the annotation must be done in modelspace.
2. Do you create multiple layers for each textstyle to match multiple viewport scales, and add layouts with viewports that match those
multiple viewport scales?
Yes, at least until Civil 3D becomes more mature.
3. Share you setups for these possiblities or add your own.
We do not fuss with layer states or filters at all. We never globally freeze a layer that is visible in any viewport and on-off is used only to temporarily isolate a layer. We never work in modelspace, instead we use a modelspace viewport dedicated soley to editing of the drawing and name our layers so they are grouped together as much as possible. We then use freeze/thaw in current viewport to display what layers are needed without affecting their visibility in the rest of the drawing. Any new layers created are reported to the supervisor who makes sure it is properly addressed in each viewport.
4. Complain to your boss that you just can't take it anymore!
Tried, it didn't work
5. The most curious question of all, does anyone use the sheet manager?
In 2006 they added the ability to recall tablyout layerstates when using the sheet set printing.
No, We have not found an acceptable way to get Sheet Manager to work with our standard sheets for profiles. We get more predictable results with little more effort by building our sheets manually. We have not deployed 2006 and will probably wait to see what gets fixed for 2007 at this point.
Sheet Set Manager (at least in 2005) was of no real use for us either. It worked OK, but we have several detail sheets that are common to each project and it proved impractical to include these in the sets.