It could be Windows. The printer driver often "tells" windows what the printable area of a sheet is and no matter how hard you try, some applications just won't print on that space. Print preview parses your document using the printer driver. Since it's misbehaving both in hardcopy and in preview, that leads me to believe that this is where your problem lies.
An application that ignores the printer margins may work. I have no idea which ones do but Desktop Publishing or, even better, graphics software may be the right answer as Cyberlinx suggests. I would use a non-Microsoft product (e.g. Adobe Pagemaker or Illustrator) since Microsoft's probably obey the Windows driver instructions.