> I'm currently laying it out in 42 point Verdanna, keeping it under 40 
> characters per line…

Standard printing and screen fonts, like Verdana, are not good for subs. The 
strokes are too thin and the detail too fine to render well in video and 
provide maximum readability. There are a number of specialized fonts, or 
weights in large font families, used for subtitles. I can't recall any of the 
specific names, but if you Google 'subtitle fonts' you can find some useful 
discussions of the issues, and also recommendations.
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