Hi Jim,
You are correct on the single 'Board Outline' issue; i.e., we can't have more than one outline. I didn't describe my issue very accurately.
The 'second' board outline I was referring to was actually the Board Outline *after* re-sizing the original, i.e., same Board Outline, just a different size.
Actually, after further investigation today and turning things 'on' and 'off', 
it turns out that what I am seeing in 'Create PDF' and also in the generated CAM document is *leftover* hatch from the *original size* Board Outline. For example, similar to my first submission, when I 'Create PDF' with 'hatch' unselected and 'pour outlines' selected, when I look at the PDF I *do not* see this hatch artifact. If I select 'hatch' and unselect 'pour outlines' I see the remnants of the hatch for the original BO size.
I have attached an image. The four holes at the extremes of the image are on the hatch layer associated with the original BO size. The resized BO can be seen along with it's four mounting holes at the bottom of the board. This problem, i.e., leftover hatch exists for both the top and bottom layers.
So while this isn't directly my original problem, it is related in that the leftover hatch is that which went with the original BO size.
Then, question is, 'How do I delete this residual/leftover hatch' ?
Regards,
Jim