I am curious if this was a bug though... I found at least two other references to it. One I had mentioned above in another thread and also one on this website.

http://www.experts-exchange.com/Microsoft/Development/Q_22499572.html

Could this have been an issue maybe before SP1?

You had mentioned you were still running SP1, If you have a moment, would you try this code and see if it creates two different files or the same one?

SET SAFETY OFF
CLOSE ALL
CLEAR ALL
CLEAR
lcPrinterToSet = "Acrobat Distiller" && i.e. NOT the Default Printer but another one installed
USE "E:\Program Files\Microsoft Visual FoxPro 9\Samples\Tastrade\Data\customer.dbf"
REPORT FORM "E:\Program Files\Microsoft Visual FoxPro 9\Samples\Tastrade\Reports\listcust.frx" TO FILE CUSTLIST1.TXT NOCONSOLE
lcFile = ADIR(afiles,"CUSTLIST1.TXT")
? afiles(1,2)
SET PRINTER TO NAME (lcPrinterToSet)
REPORT FORM "E:\Program Files\Microsoft Visual FoxPro 9\Samples\Tastrade\Reports\listcust.frx" TO FILE CUSTLIST2.TXT NOCONSOLE
lcFile = ADIR(afiles,"CUSTLIST2.TXT")
? afiles(1,2)

In my SP2, it does create two different size files with different printer codes in them so it appears to be working.

Thanks again, and again, and again....