Originally Posted by Sheathe
my guess would be all the addons you are updating to are 1.X addons, as such they wont work in TBC (even with enable old addons ticked), so Blizzard is going bac to the default chat frame.
Right click the "general" tab and untick "Lock Window"
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Zero mods installed and the chat frame, even when unlocked cannot be expanded beyond a certain limit.
Even with mods specifically for 2.0.
Incidently, I found that if I edited the file layout-cache.txt directly for each character, I could reset the chat frame size manually.
Next?