Bill,
I'm sorry I didn't get back to you sooner I was away until yesterday. I can offer little help or advice. I have had similar problems with Inspectfaster in the past I find the program to be very unreliable, I seem to have had almost the same exact issues generating PDF reports. For the most I have had to do the report over again at it has saved the 2nd or 3rd time I did the report.
Email the support center in Calaforina and they may be able to give you advice.
I do suggest that you make sure that Donna Ebert know you are having problems because I have documented all my issues with her.
PS
Please email me back if you were able to get the report to print.
Mark