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I don't think I've ever noticed anything particularly funny about Rosetta formatting- I just finished one on Sunday without any problem. It looks like the .mobi format doesn't justify smoothly, which is annoying but sadly not even remotely uncommon.
I'd definitely suggest going the sample chapter route a few times to see if it's annoying enough it's not readable for you! They're definitely not the worst.
Usually I wouldn't worry too much about differing file sizes, even though that's an extreme one. Rosetta tends to add a little afterward which is probably changing the size a little bit. But the rest of it likely has to do with degree of compression, cover picture sizes, etc. Rosetta has been doing ebooks for a long time and are used to working with small devices, so they streamline.
If you take a word document and do word -> html, the html file is going to be huge compared to if you just coded in simple, clean html yourself. That could cause part of the problem as well.
Sheesh, I can't stop typing this morning. Maybe I need more coffee!
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