AHA !! Table cells and table borders all have margins and padding. The first thing to do is get rid of it -- as a baseline, so you have no buffer. This looks awful, but once you realize the padding and margins are there, you can calculate how many pixels they are taking up that cannot be used in font-width calculations.
TABLE, TR, TD {margins:0 ; padding:0 ; border:0 ; }
That gets rid of everything. FYI. the border is usually 2 px by default, margins are 2 px and padding 2 px.
Now look at these tables --
http://reeddesign.co.uk/test/points-pixels.htmlhttp://net.jasonpearce.com/tools/cssfontsizes.htmlhttp://pxtoem.com/There are also calculators available, but the charts show the relations better