Hi Jim,
Welcome to PixInsight Forum and thank you so much for your words. Reading the opinions of new users who understand PixInsight's philosophy and benefits is a refreshing experience.
First, the mask building routine in ACDNR is so easy, is it available as a stand alone process to create masks for use with other processes?
Not currently, but it will be available soon. A BrightnessMask tool (the final name may change) is in our to-do list with high priority. It is really a very simple and easy-to-write, yet extremely useful tool. We normally generate these masks with the HistogramTransformation, CurvesTransformation and Convolution tools (sometimes also with ACDNR), but automating the initial steps would be great.
... is there an easy way to crop images to a specific size?
Sure. Use the DynamicCrop and Resample tools. Normally, one first uses DynamicCrop to define the part of the image to be printed. Note that if you don't want to rotate your crop, you can also define a preview and extract it as a new image (just drag the preview's view selector to the workspace, or use Preview > Make Image) instead of DynamicCrop.
Let's assume that you want to resize your image to fit into an 8.5' x 11' sheet, printed at 300 dpi resolution. Once you have cropped the image, these are the next steps:
1. Open the Resample tool (Process Explorer, Geometry category).
2. Select your image from the ListView control at the top of the tool. Alternatively, select your image and check the "Track View" button at the bottom of the tool's window.
3. Open the Resolution section and enter Horizontal = Vertical = 300. Make sure that the selected resolution units are inches, and check the Force Resolution check box.
4. At this point, on the Dimensions section you can see the final print size in pixels, centimeters and inches. If required, change the width or the height in inches, as appropriate, to cover the 8.5'x11' page. Press Enter when you change a number, or click on a different input field, to commit changes in the tool. Note that if the Preserve aspect ratio option is enabled, the tool calculates the resulting dimensions automatically when you modify either the width or the height, to keep the aspect ratio of the image unchanged.
5. The Resample tool will select an interpolation algorithm automatically, based on the amount of resampling required, and on whether the image has to be resampled down or up. The default choices usually work very well, but you may want to experiment. See this document for more information on the subject:
http://pixinsight.com/doc/docs/InterpolationAlgorithms/InterpolationAlgorithms.html6. Apply the process to your image (blue triangle, etc.).
This process can also be performed in two steps: first crop the image vertically or horizontally, as best fits your needs. Then use Resample to achieve the desired width or height. If the other dimension (the one that you didn't forced with Resample) is too large, crop the resampled image with the Crop tool.