Ok, the thing is in a working state again (testing takes simply too long :( ) and it even features some improvements. First it's even faster (3.3 hours) and second (much more importantly) it generates much more compact postscript.
The generated image.ps (originally 180MB) is now only 60MB big - without loss of information. Printers rejoice :)
The readability problem still exists of course (and I don't think there's a solution to that, aside from splitting it up into multiple A0 posters...).
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