you can try linking to a print-only style sheet with something like this:
<link rel="stylesheet" href="print.css" type="text/css" media="print" />

You're exactly right. I thought it had something to do with the popup code but I was just missing that link. Thank you.

I added the stylesheet link for my site and it helped a lot for printing regular pages. But the popup still prints out the same (too small). So I snooped around the code for Tony-Popup and didn't find a good spot to add the link. Would it be in ''view.php''?

why don't you try adding it as an HTML block to the target area that you're trying open with the popup?

btw, are you using the IFrame option? if not you should just be able to add it to your theme's css files, and then use the new print style sheet to set the rule just on the popup area.

is there a link to your site on the web that I can look at?

I tried adding the HTML block and have already added the link to the theme. Here's the page with the popup: http://www.klipnow.com/index.php/money/money-basics/...

The link in the main theme is:
<link rel="stylesheet" media="print" type="text/css" href="/index.php/tools/css/themes/creativity/print.css" />

The popup seems to inherit css from the theme so it should work fine, but doesn't. Thanks for taking time to take a look.

so I took a look at your popup's markup, and it looks like you're setting the font-size with inline styles, like this:
<p><span style="font-size: small;"><strong>IRA</strong> - Individual Retirement Account</span></p>

doing it this way makes it so you can't really override the font-size. Instead you should remove all of those inline styles from the popup (perhaps by clicking the HTML button within the content block, and removing all instances of "font-size: small;"). After that, if you want to set the size of the text within the popup, you doing do it with a css rule, something like:
.TonyPopup_boxBody p { font-size:12px; }

I sure appreciate you're hanging in there with me. It's definitely above the call of duty.

This weekend I played with some different settings and codes, trying your suggestions and others. Quite a puzzle. I'm starting to get the impression there are multiple problems going on, none of which have to do with the popup code. And that's where this all started, I assumed the popup code was messing things up.

Most likely, I'll just attack this from a different angle altogether. Again, thanks for going the extra mile.