I'm running a registered copy of BGE, using version 1.5. I've created 5 images to use as a health counter dropping from 4 to 0 and the only difference between them is the number in the centre, 4 to 1 and a skull representing the 0. They are all 128x128 pixels and as I used GIMP and just changed the number in the centre before exporting each image as a png file they should be identical in size.
I then go in to BGE and place a component. When I cycle through the 5 images in the folder images 0 to 3 are the same size but 4 is bigger. If I create them as separate components 4 looks bigger on the game board although its size is shown as 50% (as are the other components).
So I create another image, rename the offending image to "old health 4.png" and put the new one in the folder. Then I go into BGE, place a component and then the offending image is the same size as the others, but the new one is larger!
I want all the tokens to have the correct names, so I go back in and rename the tokens - now 4 is showing bigger again!
I've closed and re-opened BGE to see if it flushes things out but it hasn't had any effect.
Any idea what I maybe missing (apart from the hair I'm pulling out

Thanks in advance - it's a brilliant program and I'm enjoying using it.
Regards,
Alan