Kenneth Payne:
Hi to everybody with problems with font size!
I improved my kmail problem by visiting the SUSE support database. There's an article there about too big or too small fonts in KDE.
It seems you could be running at the wrong display size. Physically measure your display and see what its size is in millimeters.
I had a "Display Size" entry in XF86Config of 320 240.
I replaced this by something more like the real size of the monitor - 360 270.
Presumably I had the wrong values in the config file because my X setup did not go smoothly.
Voila! Now I get smaller and neater fonts. I still can't get kmail to shrink my message body text but it doesn't matter now because it's OK as it is.
Hm, my monitor is exactly 320x240, but I took my calculator and calculated what must these dimensions be with 96x96 dpi and my working resolution. So I replaced the right values with wrong ones and all is Ok now :) ain