Sorry to hear about the stubborn user; FWIW, Microsoft recommends that a Word doc should not exceed 32mb; While you might reach 60mb you create system instability. You should be using the Word Outline feature to create sub-documents. It likely won't print correctly due to the file size. Also, be aware that sub-docs are also 'unstable' and tend to become easily corrupted. The print to PS then distill is your only option.