It's good to reinvent the wheel. You discover for yourself just WHY FontStruct is not suitable for curves beyond a certain point.
The more curvacious you make it, the more problems you cause.

But along the way discovering this I have learned an awful lot about what I'd call "visual" maths. And it's fascinating. Just how certain bricks do not wish to be placed where you first thought they shoud go. It's all to do with tangents and intersects and whatnot.

Even if this font is ultimately a failure, it's been great fun to bash my head against the limitation of having basically just two angles to work with. It forces ordered thinking, no bad thing when giving the world Yet Another Font.

It certainly was worth doing. After this one I went on to do another fine-grained font (slabfest) but came unstuck with timeout errors. I managed to get the lower-case out but couldn't add any upper case without the FontStructor spitting the dummy. shame. I suppose I could have split the upper and lower cases into two files, but it would have made 'on-the-fly' comparisons a bit of a logistical difficulty.

I think that Mr Meek has since addressed the large-file timeout issue. But I haven't gone back to these huge fonts for another reason: I can't zoom away far enough to see each character all at once! (Well, that's my own fault for creating such a gigantic glyph.) A bigger zoom range would be nice... just suggesting...