Finally got IE9 fixed. Changed font size to 12 in IE9 and printed again ... no joy !
The printed text was small (same as before).
Here is an example of a good print and a small print (unfortunately the scanned images don't show the problem very well(both are from my wife's email):
Good Print(1st) .......................................Small print(2nd)

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As you can see, the email header ( Name, To field, etc) and the email image are OK in both emails... but the text in the (2nd) is smaller (difficult for wife to read).