When you compile your report in iReports, do you see any problems in the Problems tab?
I’ve seen cases where the report runs fine in iReports, but iReports IS seeing problems, but just quietly reporting them in the Problems tab, whereas if you run the report on the Server, like the Jasper Plugin does, it raises an error.
I’ve checked the jasper forums, but no-one reported this yet.
Did you get any further with it? Does it go wrong with all reports? Or just one? Or all reports that were build in iReports 2.0.4?
Paul
BTW: teh pen tag does seem to be related to the borders, as you suggested