Wrong Font for Outlook Express Printing
"the Outlook Express printer font depends on the screen font that you select in Internet Explorer.
In other words, if you increase the screen font for viewing web pages with Internet Explorer, you will also increase the print font for printing emails with Outlook Express.
To change the Internet Explorer screen font, select View from the toolbar, then select Text Size. I recommend you stick with the Medium setting. If the changes don't take effect right away, close Explorer and Outlook Express, then re-open Outlook Express and try to print."