Ok, I have been re-working the DFX custom font here, and I think I have come up with a fix for the fonts displaying wrong at 800 x 480 resolution.
If someone could test this out on their system, and let me know how it works for you at 800 x 480, that would be great.
You will have to install the new font in the attached zip file, and copy the BottomButtons.txt to the skin folder. That's it.
Someone give it a try and report back soon as you get a chance.
Here is a screen cap in my desktop system, with the general ini set to show width and height 800 x 480