HNDigest (https://hndigest.com) is profitable some months, others not so much. Turns out it's quite expensive to send a ton of emails if you don't have sponsors.
I should probably spend more time finding sponsorship.
I see what you mean. I'll investigate it, however designing html emails is kinda like black magic (although less nowadays since Gmail supports responsive design from October 2016) so no promises!
Question: Is there any way you could make the newsletter so that long titles don't text wrap on wide screens? Example: http://imgur.com/a/vlCE8