May 6, 2011 
How to add a Sub Level custom Navigation to SharePoint 2010 Global Navigation?
I was able to follow instructions from : http://www.estruyf.be/blog/adding-a-subsites-navigation-level-under-the-global-navigation-row/ and create custom SharePoint 2010 sub level navigation.
This is what I have done to create new Sub Level Navigation in SharePoint 2010
1. Go to http://www.estruyf.be/blog/adding-a-subsites-navigation-level-under-the-global-navigation-row/ and click on download file link
2. Open your SharePoint 2010 site using SharePoint Designer 2010
3. Create a new master page and past the code which you just copied from the link. In my case, I am calling my master page as custom_2.master
4. Check in and publish the master page
5. Click on the drop down and select Approve/Reject
6. Approval Status
7. In your SharePoint site, Site Actions | Site Settings | under look and feel select Master Page. Make sure your new master page is selected and click ok
8. Now go back to your top level site and create some sub sites. If you don’t
see the navigation this way. Go to Step 9
9. Site Actions | Site Settings | Navigation (Under Look and Feel) and check Show sub sites
10. By changing the color of the CSS, you can create different SharePoint 2010 Sub Site navigation
Sample Custom Sub Level Navigation in SharePoint 2010
Cool to see it in action on another SharePoint site.
Thank you for the mention.
I tried it and it works well. However the order of sub site tab doesn’t change when it is sorted manually in Site Navigation settings. Can it be done? Thanks.