Okay, here's an opportunity for a point of information.
There is a difference in how Truetype and Type 1 curves are expressed. Even though our group font won't be going to a Type 1 version, Opentype can support the two types of geometry (TT and T1). Once in a while you might see older versions of Xara report that highlighted text is "Opentype (PS)", which is confusing, and means internally, Type 1 geometry was used in building the glyphs.
Truetype uses quadratic B-splines along curves. Mathematically, it's a verbose language and most of the time a TT font will be of larger file size than an equivalent OTF. Why? Because B-splines require 2 control points off the curve and two on the curve to express a path segment. This produces really smooth curves and is probably why Bill got fewer or no errors when he had FontLab translate a glyph from Type 1 to Truetype.
Here's a screen cap of a Truetype glyph in FontLab, expressed in its native structure and as Type 1 curves.
Me, I'd like to keep with Type 1 curves while working this font together, because it's easier to manipulate 2 control handles over 4.
Let's see how this goes. Agreed, FontLab's auditing feature is a piece of...inaccurate code.
—g
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