> 1) three layers filled with: bg color, border color, fg color
> 2) create rounded selection (25% radius)

What if you add 2b) save selection as channel?  Then you can scale the
image and reload the selection from the channel...

> 3) select border color layer, invert and clear
> 4) select fg color layer, shrink selection by 1, invert and clear
> 5) save as .png.
> the problem is I have to redo all this if I resize the image.

I may have misunderstood the question - let me know if this isn't helpful...

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