rocknbil - 12:01 am on May 30, 2010 (gmt 0)
Look for png2ico (also free.) Compile an ico with **both** a 16x16 and 32x32. That is, the command is something like
png2ico favicon.ico image1.png image2.png
... and it will create the favicon.ico with both versions. The browser will use whatever it thinks it needs. You can compile in as many as you want, I think.