This happens because Mail in Mac OS X 10.2.8 or earlier automatically scales printed text based on the width of your Mail message window. The wider the window, the smaller the printed text.
What can you do? Before printing or saving as a PDF, change the size of the window by positioning the pointer over the lower-right window corner (the resize control) and dragging.
- If the printed text is too small, make the Mail message window more narrow.
- If the printed text is too big, make the Mail message window wider.
Or you could do this:
1. Copy the text of the message.
2. Open a different text application, such as TextEdit.
3. Paste your email address into the new document.
4. From the File menu, choose Print.
Tip: You can preview the printout by clicking the Preview button in the print dialogue.