I have built full em zoomable sites in the past. In fact, every dimension in my company site ( http://kingdesk.com ) is em based. In all my recent work, I have abandoned such practice for four reasons:
- EM Maintenance is a b*tch. It is one thing to get the math right on nested elements during the initial design, but reorienting yourself after some time away is burdensome – to the point of just puting in fixed units at the expense of breaking the em-zooming effect.
- Browsers have come a long way in the past 2 years. The current version of every major browser supports page zooming natively.
- It is true that these sites are less accessible to visually impaired users in IE6, but there are abundant freely available tools for them that resolve this issue. If there is not a reasonable alternative, I have a moral obligation to facilitate their need. If there are 4 ADA accessible ramps to my front door, I'm not going to demo the steps and replace them with a 5th.
- I figure it saves me 20% in my design time.
I now design exclusively in fixed units, and have never once had a problem or complaint.
Oh, and if you're wondering, I no longer try to make sites look pixel perfect in IE6. They are still navigable, and decent looking. But time moves on and 9 year old browsers receive the attention they are due.