When you changed to a distance field font did you the also reduce the size and scale the text node? The whole purpose of distance field fonts is that you can keep them relatively small and then scale them and retain nice crisp edges.
The issue you stumbled upon is a bug in the current editor, and it’s not anything we will solve. We just did a test in the new editor and it rendered the large bitmap font properly. If you wish to test the new editor (which is getting more production ready every day) please send @Ragnar_Svensson a PM.