Yep, what Hisst said.

(except for the printer part--I'm not able to test on mine yet)

ALLINONE

ALLINONE

ALLINONE

Isn't there a way with Acrobat to do 'layers', so that the user can turn on/off an overlay of the grid they want?

Someone on RPGNow sells an acrobat product that is sort of configurable like that... look at the 0one customizable battlemaps. They have a free demo.

As a test I tried printing the grid with an old system.

HP DeskJet 720C driver v10.3

Minimum margins set:
Top 0.04"
Bottom 0.46"
Left 0.25"
Right 0.25"

Adobe Acrobat Reader 5.0.5

There are four basic choices for printing with 5.0.5:
Shrink oversized pages
Expand small pages
Auto rotate and center
No boxes checked

The grid was printed on 8.5" x 11" US letter size paper. The No Boxes Checked, Shrink oversized pages, and Auto rotate and center choices had the grid print at 1.5" x 1.5" with no croping. The Expand small pages indicated that it would print at 141.4%, but the grid printed only 1 mm larger in height and width for each square with no croping.

Looks like ya got a winner.