Unfortunatley I get the same problem when using TPowerFont and DO3D. For now I'll just use TextOut() but this still doesnt solve the problem of antialiasing occuring in places where I dont want it to happen.

It doesnt seem to happen everywhere though, just on the characters themselves.

The code I use to draw peoples faces is:

Faces.Items[Face].Draw(Surface,X+XFaceInc[Frame],Y+5,Frame);
Eyes.Items[Eye].Draw(Surface,X+XEyeInc[Frame],Y+YEyeInc[Frame],Frame);
Hairs.Items[Hair].Draw(Surface,X+XHairInc[Frame],Y,Frame);

So am really not sure why its being anti-aliased when other parts of the surface such as the map tiles and background layers are left untouched....