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Final should be 24 x 36 inches (poster). I'm messing with the fonts right now, trying to make it more readable (I'm at like 5pt for most of it). When I changed every layer to settings that changed the font as well as spacing, leading, etc. in order for a different font to take up the same amount of space (I used one of my text layers to play around with it until the settings were good), some text layers were perfect while others seemed to have too much text, i.e. they need to be downsized further. Why is that? Am I doing something wrong? How can the same settings applied to multiple layers of text that matched perfectly before cause discontinuities?

Also, I'm keeping the face itself black. The text will most likely be blue with the red hat. The hat must be red, and blue is in the triad color scheme.