Creating an HTML email that displays the way you want to in email clients, can be very difficult, if not impossible. Unfortunately, email clients do not use the latest and greatest web browsers when displaying emails, and they can also restrict what should be allowed (and with good reasons).
No matter how much you might love CSS-based layouts, table-based layout is still the way to go for HTML emails. You can still use CSS for other things, of course, but in some cases it will need to be inline. The best looking HTML emails I've seen, are largely made up of tables and big images - simply because unlike on normal web pages it is nigh on impossible to create the equivalent using good web development practices. HTML email is a world of its own.
You should also test the emails in as many email clients as you can - and while it can be cumbersome to install all the different clients, you can also use services such as Litmus, MailChimp and CampaignMonitor (see also this question). Personally I have had good experiences with Litmus.
Good luck, creating HTML emails can be quite messy!