Anyone know if it's possible to configure the format (foreground color, background color, font, window size & loation) of the commaond window that the "Open Command Window Here" powertoy opens up?

Should be the same as a regular command prompt. As for configuring it, I'm not sure exactly how. A good way to find out would probably be with a registry snapshot program. I like Advanced Registry Tracer personally.

http://www.elcomsoft.com/art.html

There is also Active Registry Monitor

Anyone know if it's possible to configure the format (foreground color, background color, font, window size & loation) of the commaond window that the "Open Command Window Here" powertoy opens up?

Open a command window up, click on the icon in the upper left corner, and choose propeties. Set it up the way you want and when you click OK, it will ask, do you want these settings just for the current command window, or for all command windows from then on.