Strange, the problem is now fixed. I hve reinstalled a new window manager -- sawfish -- and reinstalled KDE AND reinstalled XFree86.
This didn't fix the problem.
So I sat here and dorked with every single line of the XF86Config file.
Right here was the error, look at the line commented out.
VendorName "Monitor Vendor"
# DisplaySize 143 108
HorizSync 30.0 - 110.0
VertRefresh 50.0 - 160.0
I commented that out and all fonts returned to normal. I have no answers as I am not entirely sure what that means now. I thought it was the MMxMM dimension of your viewable area but it seems I may be wrong.
Anyhow that fixed it, thanks for poking in guys