Hi Felix

Thank you for the reply with info.

and other places have not worked.

If you're using a binary NVidia driver, you should be able to use 'Option
"DPI" "118x118"' in xorg.conf. If not that driver, try 'Option "NoRandr"' in
'Section "Device"' in conjuction with the traditional DisplaySize option in
xorg.conf (which you'll need to create if it doesn't exist). You might also
need to disable EDID and/or DDC, depending on gfxchip/driver. Make sure also
your your environment doesn't contain an Xft.dpi of anything other than the
DPI you prefer. Note also that the report from xdpyinfo does not always equal
the DPI that apps like Gecko are using. Use

Xorg.0.log
http://pastebin.com/q2DRbrj3

Interesting bits:

(II) intel(0): RandR 1.2 enabled, ignore the following RandR disabled
message.
(II) intel(0): DPMS enabled
(==) intel(0): Intel XvMC decoder disabled
(II) intel(0): Set up textured video
(II) intel(0): direct rendering: DRI2 Enabled
(WW) intel(0): Option "NoDCC" is not used
(WW) intel(0): Option "IgnoreEDID" is not used
(WW) intel(0): Option "UseEDID" is not used
(WW) intel(0): Option "NoRandR" is not used
(WW) intel(0): Option "DPI" is not used
(--) RandR disabled

Unfortunately, with those settings and  DisplaySize     163 95 # 160dpi
It still remains 118dpi according to xdpyinfo, and also that web page

However, I had thought this change, along with the changing layout.css.dpi to
be 125 had solved the problem as it worked in a test firefox profile.
When I tested an another new profile it didn't work though. I can't explain that inconsistency in the results from my tests.

I found that passing the dpi to startx got xdpyinfo reporting the right value. "startx -- -dpi 160"

http://fm.no-ip.com/auth/dpi-screen-window.html to find out if Gecko is using
the same DPI that xdpyinfo reports. Use http://fm.no-ip.com/share/DisplaySize
to find the DisplaySize to use for commonly desired DPI values.

That first page is really useful, with the startx DPI set to 160 that now shows as 33mm, which is roughly as I expect as LCD is 118dpi

Source: xorg-server
Version: 2:1.6.4-2ubuntu4

(--) PCI:*(0:0:2:0) 8086:27ae:103c:361a Intel Corporation Mobile 945GME Express Integrated Graphics Controller rev 3, Mem @ 0xfe980000/524288, 0xd0000000/268435456, 0xfe940000/262144, I/O @ 0x0000dc80/8

Do you know how distros force the DPI to 96? I couldn't workout which file to modify to get this "startx -- -dpi 160" permanent.. I might just modify startx.

The live cd idea is a good suggestion too. I've not tried that one just yet. Any other suggestions to try appreciated.

Thank you again for the help.
Jon
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