Yeah, make it to overlay the images via javascript and not actually combine them for the preview like in here
http://users.freestuff.gr/skeftomilo...ley-maker1.htm (made by a greek friend of mine who knows javascript really good). When they use the bbcode the smilie will be created as normal. The drawback to this is that they wont be able to save the smilie via the smilie maker but only if they use it in a post...