One request...please put periods at the end of your sentences. It makes it hard to read if you don't.
You said..."Also he is a male velid cham i got him in oct 2005 and he only the size of my hand"...you didn't say how old he was when you got him....but he has to be at least 5 or 6 months old if you got him in October. He should be approaching full size soon and might just be slowing down because his growth is slowing. Does his length (you said its as long as your hand) include his tail?
You said that his casque still looks small....are you sure its a male because the female's casque doesn't grow as tall as the male's. Males have a tarsal spur that's a definite way to tell its a male. Here's a picture of the spur...
http://adcham.com/html/husbandry/glossary/tarsalspur.html
If it is a female, it could be slowing down if its carrying eggs and you should provide a place for it to lay its eggs or it could die eggbound. Veiled females can produce eggs even when not mated.
As for skinny or fat...if the tail has deep long ridges in it then he is too skinny. If its nice and round then he is fat enough. The picture of the tarsal spur shows the base of the male's tail and that's a healthy tail. The female's back legs show good (fat) size too. Its not unusual to see the ribs sticking out when he moves or reaches for something.
You said..."I cant force feed him"...I don't believe in force feeding unless there is no other option.
Re: food staying in his tank....its not a problem usually, but some veggies/fruit should be put in the cage for the insects to eat so they won't nibble on the chameleon.
You said how much you put in, but you didn't say how often. I think about 20 crickets a week would be fine for an adult male veiled. If you use other insects then you should expect to feed him less crickets than that. Temperature plays a part in his rate of digestion and temperatures that are too low can compromise the chameleon's health (ability to absorb nutrients, etc.). Do you have a full spectrum light including UVB over its cage (with no plastic or glass between the chameleon and the light) or is it exposed to direct sunlight? Do you gutload all the insects and use supplements on them too? With what and how often?
Re...growth stopping because the tank is too small....that doesn't happen.
You said..."He had suspected MBD a while ago after a fall he wasc rawling on his front legs and noticed a few bumps but now he is lifting himself up fine and the bumps are less noticable"...there are some good articles you might want to read on these sites concerning MBD and the roll that calcium, vitamins D3 and A play in it. There is lots of other information about nutrition too.
http://www.chameleonjournals.com/vet/
http://adcham.com/
http://www.chameleonnews.com/index.html
Hope this helps!