OK, done some more testing and I may not be as close as I first thought. I need some help off you guys, if anyone has any spare time (not much).
Basically, the only test devices i have are a HTC Desire Z running Gingerbread 2.3.3 and a Archos G9 101 running ICS 4.0.3. Everything seemed fine on these 2. I wanted to test further and so created a AVD of 800 x 480 with 160 Density (a basic 7" tab) running 2.3.3. This is when things got interesting.
It seems that the layout of the popup varies with android version. Up to and including Gingerbread the popup fills the screen width. Above Gingerbread the width truncates. So, I need to see some results of this running on some other devices (physical or virtual) to try get a better understanding of the behaviour and to see if my assumptions above are correct.
I have created a simple test app, if anyone has any spare time could you run it on your device and post a screenshot of the 3 tests plus details of your device. All you need to do it tap the test buttons and take screenshot. The menu items don't do anything.
Find below the test app, in APK format. .zip project removed.
Edit: please don't use the zip project. Just thought, it won't give the required results as you don't have the modified library.
My results will follow.
Thanks to anyone who has the time to try and help out with this and hopefully we will get it sorted.