I did the FontSubstitutes trick (had to add an entry for Segoe UI), but replaced it with MS Sans Serif instead of Tahoma.
MS Sans is a .fon font and not a .ttf font, which means ClearType doesn't even try to mess with it. As such, EVERY SINGLE INSTANCE, including the taskbar, pop up dialogues, etc.. ARE ALIASED! That's right - even the taskbar is clean, crisp, and pixelated.
However, I wasn't able to delete Segoe UI, even after taking ownership of the /FONTS directory. Something about it still being in use (even after a reboot)? Anyway, this meant that the control panel, etc... still used font smoothing. I, too, suffer from the
"ClearType headaches", so letting these survive wasn't an option. I tried booting into Safe Mode with Command Prompt, to delete segoeui.ttf, but still no luck.
What did, work, however, was downloading a Knoppix Live CD and using that to boot. From there, I mounted my hard drive and was able to access the NTFS Windows 7 drive (it's easier than it sounds - Knoppix is designed for that kind of thing). From there, it
was pretty easy to delete Segoe UI and all the Consolas/Callbri/C-Family of fonts. I rebooted and Windows 7 started up without a hitch.
And now, there's not a single smoothed font anywhere on my system! Hurrah!
So if I can summarize everything I did... (thanks everyone here)
- Disabled ClearType (including in IE)
- Unchecked "Smooth edges of screens fonts" from Performance -> Visual Effects. (Taskbar fonts, help, control panel, etc... remain smoothed).
- Changed all my fonts to "MS Sans Serif" under Personalize -> Windows Color
- Using regedit, added "MS Sans Serif" as the first option under HKLM->Software->Microsoft->Windows NT->Current Version->FontSubstitutes for Segoe UI and the C-Family of fonts.
- Downloaded a Knoppix Live CD and burned it to CD (http://www.knoppix.net/get.php)
- Booted from the CD and mounted the Windows 7 hard drive. Then cd'd over to /Windows/Fonts and deleted the offending files.
- Rebooted into Win 7, to see nothing but aliased fonts!
P.S. If someone knows an easier way to delete protect system files in use, you could eliminate steps 5+6. But for know, this works completely.