Hi Todd,
I was using Adobe (either Reader or Acrobat Pro) on Windows – I can look at the version tomorrow to add it to the post. The test square may have been off by 1/16th or so – the problem was, I couldn’t figure out what to do to change it. On both printers I tried I had the setting at “Actual size” – I have seen other versions of Adobe Reader where the option is “Scaling: none” and the option list on the version I used was phrased as “Actual size”; Adobe may have redone the interface as part of an upgrade or perhaps I have the professional version of Acrobat on the PC I was using – I can check for sure and upload a screenshot of my options to Flickr if anyone is interested. Staples had the same set of options available to them on their version of the Adobe Reader product as I had on my version.
Good to know about the fixed-width printing. I will go with the “Actual size” version they gave me. I think they had a few fixed length options, rather than the printer auto-calculating it, so maybe they wanted a length value as a lower bound for selecting from limited choices.
