>I have a form with around 20 small grids on it. The grids all have the headerheight set to 0 so that there is no header visible in the grids.
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>The form was designed in 800x600, and is used on this and higher resolution screens. The compiled version of the application of which this form is a part has been used for a long time by around 20 people without problem. Until today, when a new user on 800x600 resolution tried to load the form and got a message saying that the headerheight in one of the grids is set to an illegal value.
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>One difference I notice with this user's computer is that she has modified the windows (Win 98) settings to use different fonts and point size to the defaults. Could this be somehow forcing the above error? If not, any thoughts on what might be causing it?

Did you try to change Windows settings to the defaults and see if it helps?