Hi, Bill! What version of UFT are you using? There was a problem in version 2.0 in which the font size was too small and could not be changed. This was corrected in version 2.1 and later.
I don't think I've ever had this problem myself. (I thought I'd had them all--ha ha!)
Prior to sending to Word, did you choose your font sizes in UFT? [Choose Page Setup from the File menu. Select Index in the Fonts group and choose the Fonts button. Select the font, font style and size in the Fonts window.] NOTE -- The index report uses a fixed number of lines on a page. I think 9 pt or something. That might effect things, but I'm not sure. Sounds like you may have to "play" with it a bit or do a general find/replace in Word, changing each font size to the size you desire.