I've run into the same kind of problems. Although the canonical way to
fix this is to set the screen size in the X server config file, I've
found that there are rounding errors introduced with this.
What rounding errors? I must admit that my fonts look a little off which I have never chased down, but I wrote a little spreadsheet to try and find the best ratio that got close to 100dpi with no rounding error (but still had the correct aspect).
I think we only need to find values for the common screen resolutions and add them to the documentation and then we are done - no?
FWIW: for 720x576 I have the following setting which gives some slightly too large fonts:
DisplaySize 325 183
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