<< If I print a R:base report to a pdf file and then send that report to the printer the font is roughly 90% the size of the original and there are extra margins. >> I once had this same problem producing labels to PDF and then trying to print from the PDF.
What's happening is that the reader is taking your page and scaling it down to fit within an extra set of margins applied by the reader. There's an option (somewhere) to turn this "feature" off. -- Larry
