Problem solved!!
1. Install Dummy printer driver (e.g. I installed Microsoft XPS Document Writer and name it DummyCRPrinter)
2. Open the "weird report" change something insignificant, go to FILE/Print/... choose Dummy printer.. press Apply, Cancel
and Save
3. Copy the rpt to prod. srv, run the report from an user
site, press Print
The report is picking up the right( users default) printer.Basically
it can't find the Dummy printer and then search for default one)
Still, I could not figure out why it is happening with only a few of the
reports that I have developed. I tried different fonts (TTF), margins,
printers, landscape orientations, multiple columns ..) but I could not
find any pattern.
Many thanks to EdC