Once you finally get an envelope/address setup which prints corectly save it as a named "Dummy Addressed Envelope" with an address on it in a standard format :-

Name
House
Street
State
ZIP etc...

Once you get one which prints out the way you want, just open the file for any new letter on same size envelope. Save it with a new name, if you want to print it at some later date. Replace the Dummy Address with the real one and print.

I would ignore anything Word does automatically - set your document as a new blank document with the dimensions of the envelope. Put text boxes or margins where YOU want them, not where Bill Gates wants them. Save it and keep it as your own template.

Quack!
Geoff.