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When using boldface CM (CMBX-something) I get excessive white space between the letters in some words, for example august, author. Well, at least it seems excessive to me :) I know how to get rid of it, my question is what is the right way to do it? Am I missing some command that would make latex ...

a bit too late, but isnt it easier to just manually specify the marks for the problematic chapters, like this:

\chapter{very long title bla bla bla}
\markboth{very long title}{}

ofc you have to adjust it to the header/footer type you're using, but it doesnt effect the TOC entry at all. in my ...