I have had the same type of problems with merges.
 
When I merged documents the data fields would be in a different font than 
what I wanted.
 
A work around was to hilite the data file and change the file to the font I 
wanted. As long as it remained hilited it worked fine.
 
I found the problem. I would happen when the text file was a converted file 
from Word Perfect.
 
The solution was to open a blank default file. Hilite the whole text file 
except the last paragraph mark (Ctrl-Home, F8, Ctrl-End, Cursor back one 
character works best). Copy the hilited text to the blank default file.
 
The new default file doesn't have the same problem.
 
Hope this helps.
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