Maybe we can log some sense from it all:

HFONT GetWin32Font(Font fnt, int angle)
{
	LTIMING("GetWin32Font");
	static HFontEntry cache[FONTCACHE];
	ONCELOCK {
		for(int i = 0; i < FONTCACHE; i++)
			cache[i].font.Height(-30000);
	}
	HFontEntry be;
	be = cache[0];
	for(int i = 0; i < FONTCACHE; i++) {
		HFontEntry e = cache[i];
		if(i)
			cache[i] = be;
		if(e.font == fnt && e.angle == angle) {
			if(i)
				cache[0] = e;
			LOG("GetWin32Font found at " << i << " " << fnt);
			return e.hfont;
		}
		be = e;
	}
	LTIMING("GetWin32Font2");
	if(be.hfont)
		DeleteObject(be.hfont);

	LOG("GetWin32Font not found " << fnt);

	be.font = fnt;
	be.angle = angle;
	be.hfont = CreateFont(
		fnt.GetHeight() ? -abs(fnt.GetHeight()) : -12,
		fnt.GetWidth(), angle, angle, fnt.IsBold() ? FW_BOLD : FW_NORMAL,
		fnt.IsItalic(), fnt.IsUnderline(), fnt.IsStrikeout(),
		fnt.GetFace() == Font::SYMBOL ? SYMBOL_CHARSET : DEFAULT_CHARSET,
		fnt.IsTrueTypeOnly() ? OUT_TT_ONLY_PRECIS : OUT_DEFAULT_PRECIS,
		CLIP_DEFAULT_PRECIS,
		fnt.IsNonAntiAliased() ? NONANTIALIASED_QUALITY : DEFAULT_QUALITY,
		DEFAULT_PITCH|FF_DONTCARE,
		fnt.GetFaceName()
	);

	cache[0] = be;
	return be.hfont;
}

(reproduce the error and send me the log...)

BTW, I am sorry it is taking this long, I am trying but the issue is really elusive...