Finished going through Sega Saturn scans and all of those that required a re-crop were re-cropped accordingly, and everything has been uploaded to my site, as opposed to MediaFire:
http://www.ratigators.com/I kept the UI basic. Click a system, scroll through the "shelf" of games (which uses a lazy load, so only the items on screen load for bandwidth's sake, but as you scroll and items come into view, they will load), click to load the manual (which uses some basic math to determine the viewable height and do some rounding to keep the amount of cached thumbnails on the server to a minimum (100 pixel height increments)), and click any page for a full screen view (if the default manual isn't already large enough to read).
With the variable height interior manual preview images, if you are the first person ever to visit the site with your specific vertical resolution, the preview images may take slightly longer to load while the server builds them (the top thumbnails are consistent for everyone). The next time you view the same manual it will be quicker (or if someone running your same resolution has already viewed it). I did this so the server only has to build what's required.
As for what Sega Saturn covers require a re-download, I originally cropped system wide at 2800 width. The late release games with the lighter weight paper were apparently 20-30 pixels wider (Burning Rangers, Panzer Dragoon Saga, Winter Heat, etc), as were the original release titles (Daytona USA, Panzer Dragoon, etc). Oddly enough, just about every Acclaim title was also 30-40 pixels wider (with a few exceptions that were the original 2800). Also, another odd occurrence, just about every early EA title (Andretti Racing, Darklight Conflict, Madden 97, NHL 97, etc) was 20-30 pixels shorter (though, their late release 98 sports games were the 20-30 pixels wider, like NHL 98). All of the Working Design titles had wider manuals 10-50 pixels) except for Magic Knight Rayearth, which was the standard 2800 pixels wide (which was also their last game for the Saturn).
Oh, and 3D Baseball is still cut off. You now at least see the "T" in TM in the logo. Though, the way my manual was cut from the factory, there is no M at all.
The only manual that had actual text cut off on the inside was Dragon Force. On the outside, Albert Odyssey (the "G" in RPG was cutoff), Dragon Force (same "G"), Criticom (part of the "TM"), and Fighters Megamix (the edge of the tagline). Anything else was just the very right-most edge art (and as seen with my 3D Baseball, some original manuals might not have even had).