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I think you don 't use a TrueType - Font.
Try to set the font to a TrueType Font:
Var Rect : TRect;
begin
Rect := ...
Canvas.Font.Name := 'MS Song'; <-- Set Font to TT - Font
canvas.font.height := rect.bottom -rect.top - 5;
textrect(rect.left, rect.top, inttostr(Num));
end;
Now the smallest size should be 1 !!!
GL
Bug