Hi Stephen:

The fontpath is:
   /usr/X11R6/lib/X11/fonts/misc:unscaled,/usr/X11R6/lib/X11/fonts/75dpi:unscaled,
   /usr/X11R6/lib/X11/fonts/100dpi:unscaled,/usr/X11R6/lib/X11/fonts/Type1,
   /usr/X11R6/lib/X11/fonts/URW,/usr/X11R6/lib/X11/fonts/truetype,
   /usr/X11R6/lib/X11/fonts/uni:unscaled,/usr/X11R6/lib/X11/fonts/misc/sgi:unscaled
And the output of xlsfonts is:
-adobe-courier-bold-o-normal--14-140-75-75-m-90-iso8859-1
-adobe-courier-bold-o-normal--20-140-100-100-m-110-iso8859-1
-adobe-courier-bold-r-normal--14-140-75-75-m-90-iso8859-1
-adobe-courier-bold-r-normal--20-140-100-100-m-110-iso8859-1
-adobe-courier-medium-o-normal--14-140-75-75-m-90-iso8859-1
-adobe-courier-medium-o-normal--20-140-100-100-m-110-iso8859-1
-adobe-courier-medium-r-normal--14-140-75-75-m-90-iso8859-1
-adobe-courier-medium-r-normal--20-140-100-100-m-110-iso8859-1

I suspect that the window resizing is the result of the startup geometry being insufficiently large and an overcompensating resize, since when the font size is 12 or 13, the problem does not occur.  But i have no clue as to what is deciding that the geometry is insufficiently large.  Adding the -geometry parm does not resolve the problem, however, regardless of the geometry specification.

Thanks,
John

Stephen J. Turnbull wrote:
"John" == John  <wguy4biz@comcast.net> writes:
            

    John> It turns out that the problem was with the custom.el and the
    John> line: (custom-set-faces '(default ((t (:size "14pt" :family
    John> "Courier"))) t))

That is very strange.  Courier should be constant-width.  I can
imagine this happening with a proportional-width font (I've seen the
opposite happen with early versions of Xft-enabled XEmacs).

What does

xset q | grep -A 1 -i 'font.*path'
xlsfonts '-*-Courier-*-*-*-140-*-*-*-*-iso8859-1'

tell you about your font path and the courier fonts available?