(Nihil, is right, no RTF output!)

This is the procedure I would take.

You might want to open up Word by itself when Outlook is not open.
Start typing and find out which font it is using.
My money says: Times New Roman, because that is Word's default font.

What has happened is Times New Roman has inserted itself to the first line of your signature because of a previous setting of having Word as your Email Editor. The reason it's now your second line is because you screwed with it.

Now to get rid of it and to resolve this issue (since I'm not there to mess with it):

I would delete Word's normal.dot file, then I would restart Word which will recreate it. Then inside Word change the default font to Arial. Exit Word, reenter Word and check the default font. Is it now totally Arial?

If the Word default font is Arial, the go back in Outlook and check if it's solved.

If not, recreate the signature card and Vcard from a cut and paste job off a document that only contains Arial.
I noticed in Outlook 2003, the signature editor starts in Times New Roman (You can find this editor by opening a NEW email message, clicking the down arrow next to the word OPTION, then choose Email Signature. Highlight everything in each signature and delete it (so it deletes even stuff that you might not see), recreate the signature line, select all text, change the font and size, then choose replace button.

If not then, ensure all Outlook fonts are set to Arial and change the stationary font option to "Always use my fonts".

Shutdown everything and try again.

If that doesn't work, find and delete email.dot file.

Did I fumigate the little bugger?