Thanks for everyone's input. Here's what I found:
- Not the form, as it occurs on ALL reports, except non-BF modules. I'd expect to not be able to print properly from admin account, but I can.
- tried changing the paperless path using IP address and also changed path to be inside MAS90 folder. Same results, so that's not it.
- UAC has been disabled from the start, so that's not it.
- PDF tree is at same level as MAS90 folder and share is one folder above that.
I ended up creating a new network user and assigned the same security groups as original, which worked perfectly. I can only imagine that the original network users rights didn't propagate properly (even though IT guy says he forced it again last week). Lastly, I noticed that the file server has 2 Sage PDF printers, one of which is redirected to this users PC. Tried removing the printer from server, but it won't let me delete (even with Administrator account). So either the redirect is screwing it up or user rights are not propagated. Will have IT guy try to remove the redirected printer from server and try again. WHAT A PITA! So far, 4 effin hours on this task.