I don't know if you've fixed this or not, but I noticed a similar problem. I am using a report form 9"x12" (envelope) and the printer is assuming the maximum setting when it prints no matter what custom size I set. This just throws the printing out of alignment. I am using an HP8000 on a network. I believe it is a print driver problem, but no one at HP thinks the same. I recently changed from a Win98 workstation on a Win2000 server to a Win2000 workstation on the same network and that's when my problems started. If you have any of the same operating systems or printers, you may want to look to HP for the answer.