It's working. Even though I'd setup the form stock in print server properities, I still had to tweak a few things to get rid of the SWCOCX and ""page header or footer exceeds page length"" errors. These are the steps I followed:
Install the Zebra printer (in this case GK420T)
Select from printers/devices and then select Print Server Properties
Select ""create new form""
Enter name, form dimensions. In this case created form name ""2x.5"" with width of 2"" height of 1/2"" and set left, right, top and bottom margins to .01 for all. Save the form. (The non zero margins seemed to fix the ""page header...exceeded"" error)
Select the printer preferences.
Set the form to the name of the form you created in print server at the ""stocks"" option - do not use the ""user defined"" stock.
For this particular Zebra, select the ""bar code font"" tab, selected ""code128"" and then selected ""change"" changed the code 128 to use ""code 128B"", normally defaults to just ""code 128"". Apply the changes.
In Crystal reports - selected Printer Setup, and selected the Zebra printer. Verified that the printer preferences held the ""2x.5"" form option.
In Crystal page setup - allowed ""user defined"" as the choice and confirmed that the left, right, top and bottom margins where not zero - in this case they were listed as .009 for all (close enough to .01 I guess).
Crystal - detail section expert. layout, changed the width to 1.95"" and height to 1.45"" and left both gap settings to zero. (thanks David for the suggestion on sizing detail smaller than the form stock)
Added and formated the fields needed, added formula for a bar code of the serial number using BarCode128B function NOT the Sage MAS90 StringToCode128B function (I think this is where the SWCOCX error may have been generated).
Saved the Crystal report.
In WO Label printing, verfied the selected printer was the Zebra, used Printer Setup to check that the preferences for the print server form ""2x.5"" held - labels printed without error.
And I never did get the CRPE32.DLL to register...