Roland, quick question for whenever you have time.... How many chips did you order for your custom set and what breakdown between denominations did you decide on?
Since the acrylic chip carrier will hold 600 chips, I figured I might as well go ahead and order 600 chips (instead of 550). For a 600 chip, four denomination set, I've seen several different recommendations on ChipTalk and elsewhere including:
A few people have commented that the second lowest denomination chip is the most useful, which sounds plausible, so I'm currently leaning towards a 160/240/120/80 split. With 8 players, I could still run a T5000 tourney with starting stacks of 20x25, 15x100, 4x500 and 1x1000 as you suggested or, with 10 players, 16x25, 16x100, 4x500 and 1x1000. Or even run a deep stack T10000 tourney with few enough players.
BTW, I will probably use the following blind structure which smooths out some of the percentage increases in the blinds from one level to the next: