How to build your own sub-theme (6.x)
- NOTE: Before going through all the steps manually you might want to check out this - Automated ways to build a sub-theme (6.x)
- IMPORTANT: In Drupal 6, the theme system caches template files and which theme functions should be called. What that means is if you add a new theme or preprocess function to your template.php file or add a new template (.tpl.php) file to your sub-theme, you will need to rebuild the "theme registry." See http://drupal.org/node/173880#theme-registry
Drupal 6 also stores a cache of the data in .info files. If you modify any lines in your sub-theme's .info file, you MUST refresh Drupal 6's cache by simply visiting the admin/build/themes page.
The base Zen theme is designed to be easily extended by its sub-themes. You shouldn't modify any of the CSS or PHP files in the zen/ folder; but instead you should create a sub-theme of zen which is located in a folder outside of the root zen/ folder. The examples below assume zen and your sub-theme will be installed in sites/all/themes/, but any valid theme directory is acceptable (see “Getting started” for more info.)
Why? To learn why you shouldn't modify any of the files in the zen/ folder, see Why use Zen?.
- Copy the STARTERKIT folder out of the zen/ folder and rename it to be your new sub-theme. IMPORTANT: Only lowercase letters and underscores should be used for the name of your sub-theme.
For example, copy the sites/all/themes/zen/STARTERKIT folder and rename it as sites/all/themes/foo.
- Why? Each theme should reside in its own folder. Unlike in Drupal 5, sub-themes can (and should) reside in a folder separate from their base theme.
- In your new sub-theme folder, rename the STARTERKIT.info file to include the name of your new sub-theme. Then edit the .info file by changing any occurrence of STARTERKIT with the name of your sub-theme and editing the name and description field.
For example, rename the foo/STARTERKIT.info file to foo/foo.info. Edit the foo.info file and change "STARTERKIT.css" to "foo.css", change "name = Zen Sub-theme Starter Kit" to "name = Foo", and change "description = Read..." to "description = A Zen sub-theme".
- Why? The .info file describes the basic things about your theme: its name, description, features, template regions, CSS files, and JavaScript files. See the Drupal 6 Theme Guide for more info.
Then, visit your site's admin/build/themes to refresh Drupal 6's cache of .info file data.
- If you want a liquid layout for your theme, copy the layout-liquid.css from the zen/zen folder and place it in your sub-theme's folder. If you want a fixed-width layout for your theme, copy the layout-fixed.css from the zen/zen folder and place it in your sub-theme's folder. Rename the layout stylesheet to "layout.css".
For example, copy zen/zen/layout-fixed.css and rename it as foo/layout.css. Note that the .info file already has an entry for your layout.css file.
- Why? In Drupal 6 theming, if you want to modify a stylesheet included by the base theme or by a module, you should copy the stylesheet from the base theme or module's directory to your sub-theme's directory and then add the stylesheet to your .info file. See the Drupal 6 Theme Guide for more info.
- Copy the zen stylesheet from the zen folder and place it in your sub-theme's folder. Rename it to be the name of your sub-theme.
For example, copy zen/zen/zen.css and rename it as foo/foo.css. Note that the .info file already has an entry for your foo.css file and that your .info file removes the base theme's zen.css file.
- Copy the print stylesheet from the zen folder and place it in your sub-theme's folder.
For example, copy zen/zen/print.css to foo/print.css. Note that the .info file already has an entry for your print.css file.
- Copy the html-elements stylesheet from the zen folder and place it in your sub-theme's folder.
For example, copy zen/zen/html-elements.css to foo/html-elements.css. Note that the .info file already has an entry for your html-elements.css file.
- Edit the template.php and theme-settings.php files in your sub-theme's folder; replace ALL occurrences of "STARTERKIT" with the name of your sub-theme.
For example, edit foo/template.php and foo/theme-settings.php and replace "STARTERKIT" with "foo".
- Log in as an administrator on your Drupal site and go to Administer > Site building > Themes (admin/build/themes) and enable your new sub-theme.
Optional:
- Modifying Zen core stylesheets: If you decide you want to modify any of the other stylesheets in the zen folder, copy them to your sub-theme's folder before making any changes. Also, be sure the new stylesheet is included in your .info file and that you have rebuilt the theme registry.
For example, copy zen/zen/block-editing.css to foo/block-editing.css. Then edit foo/foo.info and uncomment this line to activate it:
;stylesheets[all][] = block-editing.css
to:
stylesheets[all][] = block-editing.css
Then, visit your site's admin/build/themes to refresh Drupal 6's cache of .info file data. - Modifying Zen core template files: If you decide you want to modify any of the .tpl.php template files in the zen folder, copy them to your sub-theme's folder before making any changes. And then rebuild the theme registry.
For example, copy zen/zen/page.tpl.php to foo/page.tpl.php.
- Themeing Drupal’s search form: Copy the search-theme-form.tpl.php template file from the modules/search/ folder and place it in your sub-theme's folder. And then rebuild the theme registry.
- Why? In Drupal 6 theming, if you want to modify a template included by a module, you should copy the template file from the module's directory to your sub-theme's directory and then rebuild the theme registry. See the Drupal 6 Theme Guide for more info.
- Further extensions of your sub-theme: Discover further ways to extend your sub-theme by reading Drupal 6's Theme Guide

Described process and automated script does NOT match
In particular:
#4. Automated script for zen-6.x-1.x does not remove zen.css from sub-theme's .info file. And it is not copied to subtheme's folder, so its use is prevented. What is the correct way? Copying it or not? Removing it from .info file or not?
#6. Similarly, script does not copy html-elements.css to sub-theme's folder, but it remains uncomented in .info file, so inherit from base theme is prevented. To copy, as stated in described process, or not, as in script? In this last case, leave uncommented or comment it in .info file?
I think manual and automated process should be the same.
Please, help
Suggsted Path Templates do NOT work by default.
If you create a Zen subtheme, and you want to create a suggested template, you MUST copy the root template file from the Zen folder to your subtheme. I created a CCK node type with a machine name of "case_row", and when I made a template file called page-node-add-case-row.tpl.php... it just didn't work. I rebuilt the theme cache, I did any sort of refreshing that I could. Nothing would work, so all I could do at this point was post a thread: http://drupal.org/node/488592
My suggsted tpl.php file did not work, because it was based on node.tpl.php, and that file did not exist in my subtheme
It took me several days of fruitless searching before jefke33 replied to my thread "Adding a quick input form to a view" suggested just adding the node.tpl.php to my subtheme. INSTANT FIX. There was not a single line in this document about that subject. Many other people in the issue thread that jefke33 linked to had the same problem, and were complaining that "the way this works is unintuitive".
Unintuitive? Yes. Easily documentable? Very much so.