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| quote: | | dpi should have no effect on the size of your print out. |
Oh, but it does, methinks.. Just try printing an image given a fixed size at 72 dpi, and then set the dpi to 300 dpi, for instance... Since in your previous 72 dpi there is not enough information to trully print at 300, image will be either (depending on your option):
- scaled (usually via bi-cubic resampling, but depends on your option), thus quality is lost.
- kept at the current settings, in which case the current "real" size will be distribued accordingly to the new dpi, resulting in a print trice as small.
Now, although I might be off, since I let service bureaus handle my printings when the need arises, I'm quite positif that this is the cause of dJohn's erronous printing... 
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