Thank you. I'm sure your son is very blessed to have a mommy invest so much time in his education. I don't nearly work as hard as you do. Sometimes, simple is better! I don't follow the advice from the DVD collection because I follow my instinct and believe from reading several sources that TV time should not really be exposed at such a young age and be limited.
I flash about 10-15 cards for maybe 1 min. a day, once a day. I randomly rotate the cards. Not really follow a "system" or schedule. I only let him watch "your baby can read" once a day before he gets a bath then time to sleep for the night. My homemade cards are doublesided, 3 words per page. I cant remember the font? Maybe size 44? It depends because the smaller the word, the larger the font size, the longer the word the smaller the font size.
From my experience, Powerpoint works really well. 25 words, 3x a day seems too much for him. Please don't test him, from what I recall reading it's better not to test them, just assume that he knows it! My husband got so excited seeing Ethan demonstrate his knowledge that he kept "testing" him so much that Ethan stopped doing it because he got bored. I made my husband stop and once in awhile...just for fun we would play with him while he demostrates his knowledge. He almost turning 1 years old and repeats/identifys actual words/things. He's WAY smarter than I could have imagined. Just remember to make it fun, BTW it should be fun for both of you! If it's exciting for you, it's exciting for him and vice-versa.
Hope this helps. FWI, he might be to young to demonstrate it yet, wait until min. of 9 m. to "test" if you feel it's neccasary.