In the body tag I set the font size to medium, then use a percentage to adjust the following ID and Class sizes. That way when a user readjust the font size all the text remains in the same relation as before.
The screen width I use is 780 or less. I've observed that on large monitors anything more will create a scroll bar at the bottom. I hate to lose the screen real estate to a scrollbar.
I agree that sans-serif is better to use for reading from the screen. You might want to consider serif for print outs. Studies show that serif is easier to read in print, sans-serif on the screen.
One thing I would never do is have someone change their screen size. When I find a site that requires a reconfiguration for the screen I'm not interested--too much trouble and don't expect me to take my time fixing your mistakes.
One thing that I do is adjust line height. I feel that a little extra space between lines of text helps the eye track better. This might sound a bit strange, but I've observed that some people have a harder time reading/tracking when the material is vertically before them versus material that is at an angle. This is another reason for increasing line height.
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