You need to try rubicon's solution again, and make sure that you are completely closed out of internet explorer (can be checked by task manager and looking for the iexplore.exe process). Sometimes it takes a few tries for ie to "remember" the setting, BUT it seems to only take closing the last window (as a smaller size, i.e. popup ads, etc) for it to revert to the wrong size.
I do know that there was a thread around here about resizing the ie window, but this topic comes up pretty often it seems.
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