Given that you are going to produce a newsletter (if only because you can), then include all articles for the week even if they never made it to a splash presentation on the front page. Also, include all new and updated posts for the week.
If you want a daily version then include the new articles for that day along with associated threads. I would favor a version that had all new and updated threads for the day.
Now I know this could be generated on the fly as each person requests his or her own copy. My background is big iron (read mainframes) and the policy there would be to select a date change (like GMT) and preproduce the newsletter so all we have to do is to download it. This ensures that we don't miss an article if we download Wednesday's daily version 3 hours after we downloaded Tuesday's daily version or get the same article twice if we download a few hours earlier on the second day.
RSS is nice and great for those that like it. I never liked the process that much and dropped using it. For me the chance to read MR offline on the Sony Reader sounds like something I would enjoy. I could (and would) explore areas that I don't get into now.
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