he could always use Select all, (ctrl A) then edit, Copy. Open a blank Word page and Paste. Print from that. this has added benefit of being able to leave out the To/from lines and so make it use less paper.
The size of the font in Outlook Express when printing E-mails is governed by the size of the font (or view) chosen in Internet Explorer. Go into IE, select VIEW, TEXT SIZE and alter accordingly (try smallest).
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