added a comment - - edited
Hi guys,
First up I don't know a whole lot about the inner workings of the menunav component, there is a lot of functionality built into it and I believe set methods of degradation, Moodle's integration with it is pretty basic, there is a single initialisation method in javascript-static to kick off the module, and the initial structure is produced by the core renderer if I remember correctly. Unfortunately there isn't much magic in it and thus no easy solution to this.
In regards to the skin, the problem faced here is that the YUI loader automatically loads the requirements for the menunav component, which in this case include the skin files. Unfortunately there is not much we can do about that, however there are solutions to this problem.
Restructure the use of the yui3-sam-skin class.
This would be a core change, the YUI sam skin is only put into use if the components wrapping container or the body have the `yui3-skin-sam` class. Within Moodle this class is added to the body of every page, leading every YUI component to be skinned by default.
Obviously the solution is to remove that class from the body and instead require any use of components that wish to be skinned to ensure they wrap the components content in a div with that class.
Deciding to go this way would require that we review all YUI component usages and if required modify to either print the required node in PHP or inject the node prior to component's initialisation.
The other thing to decide upon would be whether we some how give the theme a chance to include the skin or not... I'm not sure how we would go, would it be a one off thing, or per component??
Alternatively we could use another menu.
Another core change, we could of course move away from the YUI3 menunav component, and create a custom drop down menu. It wouldn't be as flexible presumably, but would have the advantage that we could include the core CSS in base, and the style CSS in standard, then theme's could copy the style CSS if they desire to use it.
I don't like this solution one bit, but it is a solution.
Stick with what we've got and write a doc on overwriting the menunav component.
I've got a mountain of stuff on my plate at the moment but I believe I could whip up a doc in a couple of hours if required. The goal of the doc would simply be to look at how to destyle the custom menu and then how to build it up again. If there is a certain theme + look you would like me to do for the doc I can, even better if there is some existing CSS.
And finally I'm open to suggestions, if any possible solutions spring to mind let me know 
My personal preference: Restructure the use of the yui3-sam-skin class is ideal if we had time to come up with a solution that worked in all cases and didn't overcomplicate the matter, however writing the doc may be a more immediate solution. Not that the first solution could potentially introduce and API change so we need to get this sorted ASAP.
That being said perhaps I'm overlooking the obvious in someway so please you two let me know if you have any ideas!
Cheers
Sam
Martin - I think the idea is great. Unfortunately, the implementation is far from elegant as it requires overwriting the sam skin styles and loading CSS before the javascript. I spent a few hours working with the code when Sam first announced it but gave up to add this:
MDL-22450.The bottom line is that I have too many other things on my plate right now to figure out all the bugs I was getting while trying to modify the menu. If this is something you want to see in some of my future themes (as I do), perhaps Sam can add a dropdown to formfactor. Since the menu is his creation, this will give me something of a template for future themes.
BTW - the reason that the Standard theme doesn't provide much of a template is because it uses the default sam skin. I need an example of a theme that strips that away to leave just a simple bar.
The perfect situation is to not require any pre-javascript CSS and to load only the structural CSS for the dropdown into the theme. It seems strange that we did so much to give themes freedom of design choice only to add this menu that loads a specific style.
MDL-22450. The bottom line is that I have too many other things on my plate right now to figure out all the bugs I was getting while trying to modify the menu. If this is something you want to see in some of my future themes (as I do), perhaps Sam can add a dropdown to formfactor. Since the menu is his creation, this will give me something of a template for future themes. BTW - the reason that the Standard theme doesn't provide much of a template is because it uses the default sam skin. I need an example of a theme that strips that away to leave just a simple bar. The perfect situation is to not require any pre-javascript CSS and to load only the structural CSS for the dropdown into the theme. It seems strange that we did so much to give themes freedom of design choice only to add this menu that loads a specific style.