I want to make the bar code to use the shortcuts. I followed the instructions but when i paste in the new bar code it's bigger than the original. I used a paint program to get rid of the text underneath the bar code. When I had the size problem, I also tried pasting straight from the bar code program and it was also too big. Why? Does this matter? If it does matter, how can i fix it? I'm using a macintosh computer (imac).

The barcode generator only generates in multiple of .03 now... so yeah, that's possible.

As long as it looks close to the original, it is good enough. The sizing really doesn't matter to the barcode readers, which are designed to handle a variety of barcodes of different sizes and formats, scanned from varying distances. The trick is to get the employees to scan the sheet without suspecting anything.

I was able to proportionally reduce the size to the similar size of the original using Word. Any problems doing that?

No problem---in fact for the DS-230 coversheet James even tells us to do it. The barcode sizes are different for every coversheet (because NVC itself doesn't have a standard sizing), so if you are shortcutting because you don't have the original yet, how do you know what the proper sizing is except by following the instructions?