I noticed that ttmkfdir command, when ran in my truetype font directory (which includes the MS web fonts) is just crashing with a statement "Aborting". This is for XFree86-4.2.0-8. The ttmkfdir that came with version XFree86-4.2.0-6.32 works fine in the same directory.
It doesn't crash for me with any ttf fonts I've got. That means it is a specific problem with those particular fonts you've got installed causing the problem. This can be a bug in ttmkfdir, or it could be a bug in the font itself, as many fonts contain incorrect data. It's also possible the font filenames do not follow the font filenaming requirements that XFree86 requires. Without a specific reproduceable test case and/or more data, there is little I/we can do about the problem you're experiencing. Can you provide me with further details, and narrow down the problem?
Created attachment 57084
OK....I have narrowed it down to one font, mtsorts.ttf, which I am attaching.
The mtsorts.ttf font you have is buggy. http://support.microsoft.com/default.aspx?scid=kb;EN-US;q138795 Solution: Delete this font. Also, you have attached a copyrighted work of art to a publically viewable bug report, which is a violation of the font's copyright - even though it is a broken font. Please do not attach copyrighted works into bug reports. If you need to, provide a URL to a file instead please.
Wow, bug necrofications.