The thing with the tab function is that there is a limit to it. You can't just fling everything into a fuckload of categories- as you've noticed,they don't collapse as cleanly as they could. You need moderation. Too few and it's pointless, too many and it's the current clusterfuck.
And this whole layout thing needs to just be put on hold. You're really, really not putting enough thought or effort into this. You're rushing it like mad.
We have only two shitty alternatives to the layout we've had for years, one of them an off-the-cuff example of an idea (modified into ridiculousness- Moving general to the bottom so you make sure people "know the Games forum exists"? Why is this a concern at all?), and the other I think was made on the spot.
Neither should even be considered serious layouts. The forum should be asked for all it's layout suggestions- for several days. And then several days to look them over (NOT by changing the board- we're not retarded, we can imagine how a layout change works), and then a vote.
You're trying to do in three days what should take nearly three weeks.
Like, I'm trying really hard not to be a dick here, and I think I may have failed... but this really just needs to be taken slower. As I said, I would prefer the old version over anything by far, just because it's been proven. I personally just use nothing but View New Posts to find everything so layout is mostly pointless to me, but this kind of thing is huge deal to most people of this forum.