Using TV3D SDK 6.5 Open Prerelease (September 2nd, 2007).The command "TV2Dtext.TextureFont_Create" reliably produces an unwanted spot on the lowercase letter "i". My guess is that this is actually a part of the lowercase letter "j".
.TextureFont_Create("Times New Roman", "Times New Roman", 100, False, False, False, True)
Works with "Verdana", too, but there it does not seem to happen below about size 50 or so. Very much seems to be an effect of pairwise kerning.
Here's a screenshot:

Now that I look at it myself, I see that the lowercase letter "i" is actually cut off on the right! Hm. This function needs some debugging, methinks.
The antialiasing in the menu of that screenshot was done with interpolated downscaling, btw. And that's what I need those bigass fonts for. Details (off topic):
http://www.truevision3d.com/forums/game_development/tip_how_to_implement_font_antialiasing_downscaling-t16394.0.html