Have you read this?
Using Illustrator to draw typefaces

Maybe it has something to do with this:
If you observe some distortions in the shape of the imported object, make sure that it is not related to the integer coordinates. Generally, digital fonts (PostScript, TrueType or OpenType) can only include integer coordinates. On the other hand, your Illustrator artwork can have nodes with non-integer coordinates such as 161.352 pt or 354.78 mm. When FontLab imports a drawing, it has to round them to integer values — because it cannot generate fonts with non-integer coordinates. Adam Twardoch

Read the comments stupid! ;)

Sanity returned...thanks

I wouldn’t go that far, but...
you just took the words out of my mouth! ;^)

I would say that the best way of drawing letters is to make them in FL. I work with Illustrator since the first version (Illustrator 88, over 15 years) and it’s a wonderfull drawing software to create lots of things like illustration, graphs, charts, and so on, but FL has an advance over Illustrator to create typeface.

I agree, but FontLab is such a rich application I simply can’t find some things. Like, is there a way to snap to grid? Also, unfortunately I’m in a rush just to get something rolling...so I have to fall back to old habits to make them happen.

Mike’s...ummm...advice was very helpful. ;)

However, I’m totally addicted to this already and I’m not sure why I never ventured down these waters earlier (having been a graphic designer for 10 years). Guess I never had an excuse to try...

Pleasure was the best excuse I found to choose FL.