ompcabooseI haven't read this thread completely, and I might be wrong, but from what I know your hud doesn't support 16:9 aspect ratios. Is this what's causing it?
It's actually primarily designed for 16:9. However, the aspect ratio should not affect the font, but it's entirely possible the resolution does. TF2's font rendering seems to be pretty bad.
[edit] Just tested at 1366x768 specifically and it seems to be fine, at least on Linux.
So it's just my computer rendering the font poorly? Everything seems crystal clear except for the 1, 2, and 3 numerical values, so I'm not sure if that's the case. I play in windowed, no-border mode if that helps--I'd switch resolutions but 1366 by 768 is the best native resolution on my crappy monitor =/
I'll mess around with the font sizes and get back to you if anything changes.