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 Hey there, Pillhead-
I turn to Alex for your font request, as he is master af all web.
As for your question about the 04 series, this is an attribute of all bitmap fonts, which are indended to be displayed at low point sizes. The reason for their distortion at higher points is not exactly starightforward, but I will give it my best shot.
Bitmap fonts are designed according to a pixel-perfect set of rules and guidelines (this varies between both fonts and designers). Because, as a rule, text and display fonts are designed in a less precise manner, they will display seemingly perfectly at almost any point size. A display (that is, monitor) has only a certain amount of pixels per inch to work with, and therefore will sometimes overcompensate with which pixels it decides to turn black when displaying a bitmap font at higher point sizes. Thus the resulting distortion. Displays will still do this with "other" fonts, don't get me wrong, but the distortion is less evident because of the very nature of display and text fonts. Bitmap fonts, in the .ttf format, will print at any point size without distortion.
I apologize for the complexity of that little lecture, but it was off the cuff and unrefined. Given a few years I could probably pare it down and make it a little less impenetrable.
TTFN,
-Tørnquist
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