1: I was totally happy running EECH @ 1280x960 or 1024x768 and when I saw the 1.4 patch was out installed it.
As soon as I installed it I found that no matter what res i set the sim to it always displayed the HUD is 640x480!
It not a driver issue as both the Voodoo2 AND the TNT2 Ultra have the same problem!
I have de-installed the game completely, re-installed it and still no joy.
Please help me if you can (after running the game at higher rez I am not happy to return to 640x480.

I still have the hi res hud after the 1.45x patch without having to do anything different. After your reinstall you did change the res to 1024 right ?