Fonts

Smallest Font: Silkscreen
From: http://www.kottke.org/plus/type/silkscreen/

Download Silkscreen for Windows (TrueType, 22.7 KB)
Download Silkscreen for the Mac (TrueType, 26.9 KB)
Download Silkscreen for Linux** (TrueType, 17.1 KB)

In order to preserve the proper spacing and letterforms, Silkscreen should be used at 8pt. multiples (8pt., 16pt., 24pt., etc.) with anti-aliasing turned off.

Depending on which graphics program you are using with Silkscreen, you might have some problems with inconsistent letter spacing (this is not just a problem with Silkscreen, but with all fonts used at small sizes). To avoid those problems, you'll want to turn auto kerning and fractional widths (or any other sort of automatic letter spacing that your graphics program might use) off, and set the letter spacing or tracking to 0 or 0%. You'll know it's working properly when you have a 2 pixel space in between all of the letters.

Why are some of the bold characters not legible?
Silkscreen was designed to be as narrow as possible as a non-bold font. When I went to design the bold version, some of the characters were unrecognizable because of that narrowness. Rather than tinkering with the design the bolded characters of the font to make them more legible, I left them the way they were.