I found this part of the process unusual:
In total my final font-header-file is about 22kB but it was a great relief to use AI for this dumb task. Google Gemini produced a nice font for my BIOS. On individual characters I had to fix some pixel-errors
Instead of simply searching for one of the numerous font-dumps that exist on the Internet, which will already be 100% correct for all of CP437? The CGA font would be a good match (and the one he ended up using looks like it), but there are plenty of other 8x8 fonts available.