Kapil,

I agree the ligatures shouldn't be represented by bitmaps.  To deal
just with those cases a nolig file can be a copy of

    ht-fonts/iso8859/1/charset/unicode.4hf

stored at 

    ht-fonts/iso8859/1/charset/nolig/unicode.4hf

augmented with entries similar to

    'fi' ''  'fi' ''
    'fl' ''  'fl' '' 

For such a case, a compilation can be requested with a comamnd similar
to

    htlatex file "" "iso8859/1/charset/nolig/!"

or the tex4ht.env file should have its charset directory path modified
accordingly.

TeX doesn't see the htf fonts--only the postprocessor tex4ht.s deals
with them.  The tex4ht system however requires much resources from
tex.  The tex system I run provides the following resources.

 17537 strings out of 61437 
 369958 string characters out of 4947194 
 2144172 words of memory out of 8000001 
 20492 multiletter control sequences out of 10000+65535 
 8669 words of font info for 31 fonts, out of 1000000 for 1000 
 14 hyphenation exceptions out of 1000 
 36i,8n,28p,231b,2972s stack positions out of 15000i,4000n,6000p,200000b,40000s 

-eitan


 > I wasn't thinking of making bitmap fonts for the ligatures. I
 > understood the requirement as being roughly "why not use ascii text
 > in places where ascii text could suffice for conveying the content".
 > 
 > So I was thinking of just using 'ff' , 'fi' and so on in place
 > of 'ff' and so on in a font file heirarchy called "nolig". This
 > directory heirarchy would "break" ligatures for all the latin
 > characters.
 > 
 > It may also be possible to ask TeX to avoid ligatures during its run.
 > 
 > Another possibility is to check whether (X)HTML allows for "ALT" tags
 > or some CSS statement which permits font/glyph substitution.

 > P.S. While trying to create the font files using the source I noticed
 > that one needs the environment variable "extra_mem_top" to be set to
 > about "100000" or so in order for TeX to run successfully with the htf
 > source files. Is this how you run it?


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