I dont have access to word 2004 at the moment, but is the zoom (available in the 'view' menu from the toolbar in 2003, and prior I believe) the same in both?

nevermind with that; zoom of the entire doc has nothing to do with userform size.

I'll put up a test doc that has a userform and button of the same size. SO, question is, are the button and userform in the attachment the same size? if so, it seems like a resolution issue where people have chosen to have their resolution to whatever it is, where everything they look at is smaller - not just your userform.

I'll bet there is a way to dynamically size it. this MS article talks about how to do it by adding a button. you may also find this KB article useful