To anyone interested in this - I think I've finally got a grip on creating custom 
fonts, and although I'm not sure this makes me feel any better, I believe I was doing 
things correctly all along - or almost.  I have been using the Macintosh 68K linker 
along with PalmRez and Neil Rhodes PilRC plugin, and, although I'm still not 100% 
certain, I don't believe that this combination allows for Font Families and high 
density fonts - as simple as that.

I went through the steps listed here (thanks to Ben Combee)...:

http://www.palmoswerks.com/stories/storyReader$131

...to switch to using the Palm OS 68K linker and the latest version of PilRC.  I still 
can't say I understand how exactly the Palm HalfSize fonts were created to be a 
self-contained .rsrc file, but I'm pleased that I at least have my high-density fonts 
finally working.
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