Hello Jeff
All can offer is a couple of trouble shooting thoughts.
To state the obvious, you need to track down the difference between your test environment and the clients
The report writer is WYSIWYG and uses the current printer driver to create the report - try setting the printer to a pdf printer and use the same pdf driver as your client - Foxit provide a free one. This will let you know if it is a printer driver or font issue on the client side
To the best of my knowledge, the report generates twice, once for the initial display and than again when exporting or printing. Is there a memory issue on the client side that affects the second run through.
Can you send a patch to the client containing the report format and whatever process creates the data for the report or completely update the client exe to make sure every part of the client report process matches yours.
When you test, are you using exactly the same data as the client.
Can you setup remote debugging to the client site and break points in the report to trace the report execution. If not, you could modify the report and use Info() to show messages and values onscreen when certain events (break points - change of part number etc) occur and then send the modified report as a patch to the client.
Regards
Al