I believe the 'Custom' bounding box setting provided the best (clearest) results. Years ago, I used this setting to convert a truetype font into an Amiga bitmap font, then 'touched-up' the pixels of the misshaped characters manually. This was the AIAB system/shell font.
Currently, Scalos is only able to render icons fonts using ttengine.library, while the remaining elements of the UI will continue to use the bitmap fonts defined in font.prefs.
Honestly speaking, I would heartily recommend persevering with AfA-OS, as this will breathe new life into your 68k system. Download AmiKit or even AIAB, then analyse the startup-sequence of either package to see how all the patches work together with AfA-OS. Actually, forget about AIAB - it's a mess!

If you are still encountering problems with AfA-OS, contact Bernd for advice - it is quite likely that he will help you resolve the issue, or possibly even implement a fix.
I hope this helps, cheers,
James
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