I am having the same problem with firefox=3.0.5+nobinonly-
0ubuntu0.8.10.1. I can see no difference between layout.css.dpi values
-1 up to 191. At 192, the size of the Firefox icons and fonts gets much
larger. There's another "quantum" at 258.
My relevant settings are:

Screen resolution: 1680x1050
X11 resolution (set via EDI): 96dpi 
Font rendering resolution: 128dpi
Fond rendering: subpixel smoothing
Firefox preference layout.css.dpi: 0
Firefox default font size: 16

An image showing the fonts sizes in Firefox vs. OpenOffice is attached.

The only work-around I've found is to un-set "allow pages to choose
their own fonts" and set a minimum font size. This causes some pages to
render incorrectly, with overlapping boxes, etc.

** Attachment added: "Font rendering in OpenOffice vs. Firefox"
   http://launchpadlibrarian.net/20786851/Screenshot-3.png

-- 
Firefox layout.css.dpi ignored in Kubuntu
https://bugs.launchpad.net/bugs/301158
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