Colin,

Most likely, the spooler error appears when you run the REPORT FORM command. This is because the development printer name is stored in the .FRT. Sometimes you get the error, sometimes not, then it prints to the default printer because it couldn't find the one specified.

Try opening the .FRX as a table

USE MyReport.FRX
BROWSE
edit the EXPR column, and change the DRIVER, OUTPUT and DEVICE lines to look like this:
DRIVER=
DEVICE=
OUTPUT=
then find two columns named TAG and TAG2 and erase them completely.

This should solve your problem. Lots of us have written utilities to automate this annoying task!

Mike