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.
FOUND IT!!!!
Right here was the error, look at the line commented out.
Section "Monitor"
Identifier "Monitor0"
VendorName "Monitor Vendor"
ModelName "Avitron"
# DisplaySize 143 108
HorizSync 30.0 - 110.0
VertRefresh 50.0 - 160.0
EndSection
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