I actually did use a make-your-own-fonts program at one point. In fact, this comic used a custom font until Ram Lama took over the art: http://rasputincatamite.com/archive/ugly-alex-gets-startled/
Unfortunately, my alignment sucked eggs, I need dyslexic-friendly fonts, and it was way too much work. I also I'm kinda over using Witzworx. The style of the comic is changing, so this is the right time to change fonts.
The fonts I picked here (with the exception of London which I nixed already) are generally pretty readable. I also had to test them to make sure that my dyslexia wasn't going to be an issue -- which is why I typically like Comic Sans and Witzwork.
Really, I am looking for something very specific and at this point I have way too much work to reinvent the wheel. But, I appreciate the advice nonetheless.
and Old Herb