You need to change the image dimensions as stated in the docs. Not sure the point size you're using but 40 is suitable for most I guess. For example this image is 420x100: http://img505.imageshack.us/img505/347/burakrw7.gif as for the overlapping; I see that you're using the scramble option. It adds three spaces between the characters to prevent overlapping. If you remove them captcha will not be readable. Btw, any modifications you made by hand to the module internals will break if you ever upgrade or move to another machine. So, you need to maintain that updates or never upgrade the module if there is a new version. Sorry I can't help with these issues...