Essentially, the end result of a build (including all code and variables) has to fit into flash. You are running out of flash space. The only things you can do is 1) remove variables, 2) change the compiler optimisation...
If your fonts are marked as PROGMEM, then they will stay in flash and never use up your precious RAM. What symptoms are you observing to lead you to believe you are running out of RAM?
I suspect that the problem arises because the Minute field of tmElements (actually all the fields) is a uint8_t and -1 gets cast to 255. 60 * 4 = 240 which explains the 4 hour jump in Hour
Edit: ninja'd
Hi kris
Like you, I fought calibrating a simple voltage divider with a rectifier diode for ages and eventually gave up and bit the bullet and added one of these to my motorcycle instruments project. Its been rock...