In reply to A faithful sans version of Garamond?:
"I see what you mean. It's going to take a lot of manual work, though. I can use the square cap / miter bend expansion method as a starting point, but then I'll have to clean up countless intersections and clip extreme points."
Welcome to being a type designer. Hey at least you don't have to carve them in steel at actual size.
Also, I wouldn't worry at all about making extra weights until you have one absolutely nailed. Take whatever weight you think is the "normal" or "regular" weight, delete all the rest. Then work on that weight until it's perfect, until there's not one thing you want to change about it. Only after that, start working on the extra weights.
